Preconnected analyte sensors

ABSTRACT

Various analyte sensing apparatuses and associated housings are provided. Some apparatuses comprise one or more caps. Some apparatuses comprise a two-part adhesive patch. Some apparatuses comprise one or more sensor bends configured to locate and/or hold a sensor in place during mounting. Some apparatuses utilize one or more dams and/or wells to retain epoxy for securing a sensor. Some apparatuses utilize a pocket and one or more adjacent areas and various transitions for preventing epoxy from wicking to undesired areas of the apparatus. Some apparatuses include heat-sealable thermoplastic elastomers for welding a cap to the apparatus. Related methods of fabricating such apparatuses and/or housings are also provided.

INCORPORATION BY REFERENCE TO RELATED APPLICATIONS

Any and all priority claims identified in the Application Data Sheet, orany correction thereto, are hereby incorporated by reference under 37CFR 1.57. This application is a continuation of U.S. application Ser.No. 16/854,337, filed Apr. 21, 2020, which claims the benefit of U.S.Provisional Application No. 62/837,091, filed Apr. 22, 2019. Each of theaforementioned applications is incorporated by reference herein in itsentirety, and each is hereby expressly made a part of thisspecification.

TECHNICAL FIELD

The present disclosure generally relates to sensors and, moreparticularly, to analyte sensors such as continuous analyte sensors.

BACKGROUND

Diabetes mellitus is a disorder in which the pancreas cannot createsufficient insulin (Type I or insulin dependent) and/or in which insulinis not effective (Type 2 or non-insulin dependent). In the diabeticstate, the victim suffers from high blood sugar, which can cause anarray of physiological derangements associated with the deterioration ofsmall blood vessels, for example, kidney failure, skin ulcers, orbleeding into the vitreous of the eye. A hypoglycemic reaction (lowblood sugar) can be induced by an inadvertent overdose of insulin, orafter a normal dose of insulin or glucose-lowering agent accompanied byextraordinary exercise or insufficient food intake.

Conventionally, a person with diabetes carries a self-monitoring bloodglucose (SMBG) monitor, which typically requires uncomfortable fingerpricking methods. Due to the lack of comfort and convenience, a personwith diabetes normally only measures his or her glucose levels two tofour times per day. Unfortunately, such time intervals are spread so farapart that the person with diabetes likely finds out too late of ahyperglycemic or hypoglycemic condition, sometimes incurring dangerousside effects. Glucose levels may be alternatively monitored continuouslyby a sensor system including an on-skin sensor assembly. The sensorsystem may have a wireless transmitter which transmits measurement datato a receiver which can process and display information based on themeasurements.

This Background is provided to introduce a brief context for the Summaryand Detailed Description that follow. This Background is not intended tobe an aid in determining the scope of the claimed subject matter nor beviewed as limiting the claimed subject matter to implementations orembodiments that solve any or all of the disadvantages or problemspresented above.

SUMMARY

According to some embodiments, an analyte sensing apparatus is provided.The apparatus includes a housing comprising a cavity in the housing, thecavity having a first portion and a second portion. The apparatusincludes a first conductive contact and a second conductive contactdisposed within the first portion of the cavity. The apparatus includesan analyte sensor including an elongated body, a first electrode inelectrical communication with the first conductive contact, and a secondelectrode in electrical communication with the second conductivecontact. The apparatus includes a cap configured to fit on or within thecavity. The cap includes a first portion configured to be disposed overthe first portion of the cavity, a second portion, a dam disposed on aside of the cap configured to face the cavity, the dam dividing thefirst portion of the cavity from the second portion of the cavity, ashelf disposed adjacent to the dam, and a compliant component configuredto seal the first portion of the cavity from the second portion of thecavity.

In some embodiments, the apparatus includes an electronics assemblysubstrate disposed within the housing, wherein the first conductivecontact and the second conductive contact extend from the electronicsassembly substrate into the first portion of the cavity. In someembodiments, the compliant component is disposed on the shelf andconfigured to press against a portion of the analyte sensor and againsta surface of the housing within the cavity, thereby sealing the firstportion of the cavity from the second portion of the cavity. In someembodiments, the first portion of the cap includes a first holeconfigured to receive an encapsulating sealant into the first portion ofthe cavity that seals at least a portion of the analyte sensor frommoisture ingress. In some embodiments, the first portion of the capincludes a second hole configured to allow excess encapsulating sealantto flow out of the first portion of the cavity. In some embodiments, thecompliant component prevents the encapsulating sealant from flowing intothe second portion of the cavity. In some embodiments, the secondportion of the cap is configured to be disposed over the second portionof the cavity. In some embodiments, the second portion of the capincludes a slot configured to allow at least a portion of the analytesensor to pass through the cap. In some embodiments, an outside-facingsurface of the cap is configured to fit flush with an outside-facingsurface of the housing. In some embodiments, an outside-facing surfaceof the cap is configured to fit in a recessed position compared to anoutside-facing surface of the housing. In some embodiments, the cap isdisposed on an outside-facing surface of the housing. In someembodiments, the cap is secured to the cavity utilizing at least one ofa toe feature, a snap feature, a friction-fit feature, and apressure-sensitive adhesive. In some embodiments, the first portion ofthe cap and the second portion of the cap are coplanar and are formed ofa single piece. In some embodiments, the encapsulating sealant is acurable sealant configured to cure based on exposure to ultra-violetradiation and wherein the cap includes a material substantiallytransparent to the ultra-violet radiation. In some embodiments, the damis configured to contact a portion of the housing within the cavity. Insome embodiments, the compliant material includes a foam or a rubbermaterial.

In some embodiments, the apparatus includes an adhesive patch, includinga first adhesive portion configured to secure the cap to the housing andto simultaneously adhere to the housing and a second adhesive portionconfigured to adhere the first adhesive portion and the wearableassembly to a skin of a host. In some embodiments, the cap is secured tothe first adhesive portion of the adhesive patch before the cap is fiton or within the cavity of the housing. In some embodiments, the firstadhesive portion includes at least one hole configured to substantiallycoincide with at least one hole within the cap when the cap is securedto the first adhesive portion of the adhesive patch. In someembodiments, the second adhesive portion of the adhesive patch isinitially disposed on a separate liner from the first adhesive portionof the adhesive patch. In some embodiments, the second adhesive portionincludes at least one hole configured to substantially coincide with atleast one hole within the cap when the cap is secured to the secondadhesive portion of the adhesive patch.

In some embodiments, the second portion of the cap is configured to bedisposed adjacent to the second portion of the cavity. In someembodiments, the first portion of the cap extends along a first plane,the second portion of the cap extends along a second plane differentfrom the first plane, the dam includes at least a portion of the capthat extends between the first plane and the second plane and connectsthe first portion of the cap with the second portion of the cap, and atleast some of the second portion of the cap includes the shelf.

In some embodiments, the apparatus includes at least one passivationlayer deposited over at least a portion of the first portion of thecavity and over at least a portion of the sensor, the at least onepassivation layer preventing moisture ingress to the portion of thesensor. In some embodiments, the apparatus includes one or moreconductive traces deposited on the at least one passivation layer andelectrically coupled to one of the first conductive contact and thesecond conductive contact.

According to some embodiments, an analyte sensing apparatus includes ahousing, an electronics assembly substrate disposed within the housing,and an analyte senor including an elongated body having at least a firstbend.

In some embodiments, the first bend is oriented such that a portion ofthe elongated body distal of the first bend extends substantiallyparallel to a plane of the electronics assembly substrate and a portionof the elongated body proximal to the first bend extends substantiallyperpendicular to the plane of the electronics assembly substrate and atleast partially into the electronics assembly substrate. In someembodiments, the housing includes a recess and at least some of theportion of the elongated body proximal to the first bend extends throughthe electronics assembly substrate and into the recess. In someembodiments, the portion of the elongated body proximal to the firstbend exerts a biasing force against a portion of the electronicsassembly substrate, thereby securing the analyte sensor in a desiredorientation with respect to the electronics assembly substrate.

In some embodiments, the first bend is oriented such that a portion ofthe elongated body distal of the first bend extends substantiallyparallel to a plane of the electronics assembly substrate and a portionof the elongated body proximal to the first bend extends substantiallyperpendicular to the plane of the electronics assembly substrate andaway from the electronics assembly substrate. In some embodiments, thehousing further includes a recess in a sidewall of the housing, at leastsome of the portion of the elongated body proximal to the first bendextending within the recess and thereby restraining the analyte sensorin a desired orientation with respect to the electronics assemblysubstrate. In some embodiments, the portion of the elongated bodyproximal to the first bend exerts a biasing force against a portion ofthe housing, thereby securing the analyte sensor in a desiredorientation with respect to the electronics assembly substrate. In someembodiments, the elongated body of the analyte sensor includes at leastone additional bend proximal to the first bend. The at least oneadditional bend causes at least a first part of the portion of theelongated body proximal to the first bend and distal to the at least oneadditional bend to extend in a first direction within the recess andexert a first biasing force at a first location along the recess, and atleast a second part of the portion of the elongated body proximal to thefirst bend and proximal to the at least one additional bend to extend ina second direction within the recess and exert a second biasing force ata second location along the recess, thereby securing the analyte sensorin a desired orientation with respect to the electronics assemblysubstrate.

In some embodiments, the first bend is oriented such that a portion ofthe elongated body distal of the first bend extends in a first directionsubstantially parallel to a plane of the electronics assembly substrateand a portion of the elongated body proximal to the first bend extendsin a second direction that is different from the first direction butalso substantially parallel to the plane of the electronics assemblysubstrate. In some embodiments, the elongated body of the analyte sensorincludes at least one additional bend proximal to the first bend. The atleast one additional bend causes at least a first part of the portion ofthe elongated body proximal to the first bend and distal to the at leastone additional bend to extend in the second direction and exert a firstbiasing force at a first location along one of the housing and theelectronics assembly substrate, and at least a second part of theportion of the elongated body proximal to the first bend and proximal tothe at least one additional bend to extend in a third directionsubstantially parallel to the plane of the electronics assemblysubstrate and exert a second biasing force at a second location alongone of the housing and the electronics assembly substrate, therebysecuring the analyte sensor in a desired orientation with respect to theelectronics assembly substrate. In some embodiments, the electronicassembly substrate includes a post and the first bend is oriented suchthat a portion of the elongated body distal of the first bend extends ina first direction substantially parallel to a plane of the electronicsassembly substrate and a portion of the elongated body proximal to thefirst bend extends substantially along a perimeter of the post, therebysecuring the analyte sensor in a desired orientation with respect to theelectronics assembly substrate. In some embodiments, the portion of theelongated body distal of the first bend exerts a first biasing force ata first location along one of the housing and the electronics assemblysubstrate, thereby securing the analyte sensor in a desired orientationwith respect to the electronics assembly substrate. In some embodiments,the first bend exerts a second biasing force at a second location alongone of the housing and the electronics assembly substrate, therebyfurther securing the analyte sensor in the desired orientation. In someembodiments, the portion of the elongated body proximal of the firstbend exerts a third biasing force at a third location along one of thehousing and the electronics assembly substrate, thereby further securingthe analyte sensor in the desired orientation. In some embodiments, thesecond biasing force is exerted in a substantially opposite directionfrom the third biasing force. In some embodiments, the first biasingforce is exerted in a substantially perpendicular direction to each ofthe second biasing force and the third biasing force. In someembodiments, the first bend provides a first torque about the first bendthat pushes the portion of the elongated body distal of the first bendagainst the first location. In some embodiments, the first bend providesa second torque about the first bend that pushes the portion of theelongated body proximal of the first bend against the third location.

According to some embodiments, an analyte sensing apparatus includes ahousing having a cavity having a first portion and a second portion, afirst conductive contact disposed in the first portion of the cavity, asecond conductive contact disposed in the first portion of the cavity,and a first well encompassing the first conductive contact. The firstwell is defined by a first dam disposed adjacent to a first side of thefirst conductive contact, and a second dam disposed adjacent to a secondside of the first conductive contact opposite the first side. Theapparatus includes an analyte sensor having an elongated body, a firstelectrode in electrical communication with the first conductive contact,and a second electrode in electrical communication with the secondconductive contact, wherein the analyte sensor rests on the first damand on the second dam.

In some embodiments, the apparatus includes an electronics assemblysubstrate disposed within the housing, wherein the first conductivecontact and the second conductive contact extend from the electronicsassembly substrate into the first portion of the cavity. In someembodiments, the first dam and the second dam each include a slopedcross-section, the analyte sensor resting on a lowest point of thesloped cross-section of the first dam and on a lowest point of thesloped cross-section of the second dam. In some embodiments, the slopedcross-sections of the first and second dams are one oftriangularly-recessed, parabolically-recessed, semi-circularly-recessedor hyperbolically-recessed cross-sections. In some embodiments, theapparatus includes conductive epoxy disposed over at least a portion ofthe first conductive contact within the first well. In some embodiments,the conductive epoxy is disposed at least to a height of the lowestpoint of the sloped cross-section of the first dam or of the lowestpoint of the sloped cross-section of the second dam such that the firstelectrode of the analyte sensor is in direct physical and electricalcontact with the conductive epoxy.

According to some embodiments, an analyte sensing apparatus housingincludes a first pocket having a first pocket base, a first adjacentarea abutting a first side of the first pocket, the first adjacent areahaving a first adjacent area base and a first transition between thefirst pocket base and the first adjacent area base, and a secondadjacent area abutting a second side of the first pocket, the secondadjacent area having a second adjacent area base and a second transitionbetween the first pocket base and the second adjacent area base. Thefirst and second adjacent areas are continuous with the first pocket.

In some embodiments, the housing includes an electronics assemblysubstrate disposed within the housing. In some embodiments, the firstpocket has a substantially rectangular-shaped geometry such thatsidewalls of the first pocket are substantially planar and meet oneanother to form angled corners. In some embodiments, the first pockethas a substantially rounded rectangular-shaped geometry such thatportions of sidewalls of the first pocket are substantially planar whileother portions of the sidewalls that connect the substantially planarportions are curved. In some embodiments, the first pocket has asubstantially diamond-shaped geometry such that sidewalls of the firstpocket are substantially planar and meet one another to form angledcorners. In some embodiments, the first pocket has a substantiallyrounded diamond-shaped geometry such that portions of sidewalls of thefirst pocket are substantially planar while other portions of thesidewalls that connect the substantially planar portions are curved. Insome embodiments, the first pocket has a substantially polygonal-shapedgeometry such that sidewalls of the first pocket are substantiallyplanar and meet one another to form angled corners. In some embodiments,the first pocket has a substantially rounded polygonal-shaped geometrysuch that portions of sidewalls of the first pocket are substantiallyplanar while other portions of the sidewalls that connect thesubstantially planar portions are curved. In some embodiments, at leastone of the first adjacent area base and the second adjacent area baseare disposed at an elevated height compared to the first pocket base. Insome embodiments, the at least one of the first transition and thesecond transition step up from the first pocket base. In someembodiments, the elevated height is approximately 0.5 millimeters. Insome embodiments, the housing includes epoxy disposed on the pocketbase, wherein the epoxy forms an upward-inflecting meniscus at the atleast one of the first and second transitions and the elevated heightexceeds a height of the upward-inflecting meniscus. In some embodiments,the elevated height is a function of the first predetermined amount andat least one of a viscosity, a surface energy and a surface tensioncharacteristic of the epoxy. In some embodiments, at least one of thefirst adjacent area base and the second adjacent area base are disposedat a same height as the first pocket base. In some embodiments, at leastone of the first transition and the second transition are flush with thefirst pocket base. In some embodiments, at least one of the firstadjacent area base and the second adjacent area base are disposed at alower height compared to the first pocket base. In some embodiments, atleast one of the first transition and the second transition step downfrom the first pocket base. In some embodiments, the lower height isapproximately 0.5 millimeters. In some embodiments, the housing includesepoxy disposed on the pocket base, wherein the epoxy forms adownward-inflecting meniscus at the at least one of the first and secondtransitions. In some embodiments, the epoxy adheres to the at least oneof the first and second transitions and inhibits the epoxy from creepinginto the at least one of the first and second transitions. In someembodiments, one of the first adjacent area base and the second adjacentarea base is disposed at a lower height compared to the first pocketbase and the other of the first adjacent area base and the secondadjacent area base is disposed at an elevated height compared to thefirst pocket base. In some embodiments, both of the first adjacent areabase and the second adjacent area base is disposed at a lower heightcompared to the first pocket base. In some embodiments, the firstadjacent area has any of a substantially rectangular-shaped geometry, asubstantially rounded rectangular-shaped geometry, a substantiallydiamond-shaped geometry, a substantially rounded diamond-shapedgeometry, a substantially polygonal-shaped geometry, a substantiallyrounded polygonal-shaped geometry, and a substantially irregular-shapedgeometry. In some embodiments, the second adjacent area has any of asubstantially rectangular-shaped geometry, a substantially roundedrectangular-shaped geometry, a substantially diamond-shaped geometry, asubstantially rounded diamond-shaped geometry, a substantiallypolygonal-shaped geometry, a substantially rounded polygonal-shapedgeometry, and a substantially irregular-shaped geometry. In someembodiments, sidewalls of the first pocket are disposed substantiallyperpendicular to the first pocket base. In some embodiments, sidewallsof the first pocket are disposed at an angle from substantiallyperpendicular to the first pocket base. In some embodiments, sidewallsof at least one of the first and second adjacent areas are disposedsubstantially perpendicular to the respective first and second adjacentarea bases. In some embodiments, sidewalls of at least one of the firstand second adjacent areas are disposed at an angle from substantiallyperpendicular to the respective first and second adjacent area bases. Insome embodiments, sidewalls of at least one of the first and secondtransitions are disposed substantially perpendicular to the first pocketbase. In some embodiments, sidewalls of at least one of the first andsecond transitions are disposed at an angle from substantiallyperpendicular to the first pocket base. In some embodiments, sidewallsof at least one of the first and second transitions are rounded suchthat angled corners are not formed at the at least one of the first andsecond transitions. In some embodiments, a first width of the firsttransition and a second width of the second transition are substantiallywithin the range of 0.5 mm and 2.0 mm. In some embodiments, a firstwidth of the first transition is greater than a second width of thesecond transition. In some embodiments, a first width of the firsttransition is less than a second width of the second transition. In someembodiments, the housing includes a conductive contact disposed in thefirst adjacent area or in the second adjacent area. In some embodiments,the housing includes an analyte sensor having an elongated body, a firstelectrode, and a second electrode. One of the first electrode and thesecond electrode is in electrical communication with the conductivecontact.

In some embodiments, the housing includes a post disposed in the firstadjacent area or in the second adjacent area, and epoxy disposed on thepost. A portion of the analyte sensor is disposed in the epoxy disposedon the post. In some embodiments, the epoxy disposed on the post exertsa centering force on the portion of the analyte sensor disposed thereinsuch that the analyte sensor is aligned substantially along a centerlineof the post. In some embodiments, the post has a substantiallysymmetrical geometry about a centerline of the post.

In some embodiments, the first pocket base has a first surface energyand the first adjacent area base has a second surface energy differentfrom the first surface energy. In some embodiments, the second adjacentarea base has one of the second surface energy and a third surfaceenergy different from the first and second surface energies.

In some embodiments, the housing includes a third adjacent area abuttingthe first pocket, the third adjacent area having a third adjacent areabase disposed at a lower elevation than a top surface of a sidewall ofthe first pocket and a third transition between the top surface of thesidewall of the first pocket and the third adjacent area base. In someembodiments, epoxy disposed within the first pocket adheres to the thirdtransition and inhibits the epoxy from creeping into the third adjacentarea. In some embodiments, the third adjacent area is configured toaccept at least an excess portion of epoxy disposed within the firstpocket, thereby preventing the epoxy from creeping into at least one ofthe first and second adjacent areas.

According to some embodiments, analyte sensing apparatus includes ahousing. The housing includes a first pocket having a first pocket base,a first adjacent area abutting a first side of the first pocket, thefirst adjacent area having a first adjacent area base and a firsttransition between the first pocket base and the first adjacent areabase, a second adjacent area abutting a second side of the first pocket,the second adjacent area having a second adjacent area base and a secondtransition between the first pocket base and the second adjacent areabase, and a conductive contact disposed in the first adjacent area or inthe second adjacent area. The apparatus includes an electronics assemblysubstrate disposed within the housing and electrically coupled to theconductive contact. The apparatus includes an analyte sensor includingat least one electrode in electrical communication with the conductivecontact and epoxy disposed on the first pocket base, the epoxy securingat least a portion of the analyte sensor to the first pocket base.

In some embodiments, at least one of the first adjacent area base andthe second adjacent area base are disposed at an elevated heightcompared to the first pocket base. In some embodiments, the epoxy formsan upward-inflecting meniscus at the at least one of the first andsecond transitions and the elevated height exceeds a height of theupward-inflecting meniscus. In some embodiments, at least one of thefirst adjacent area base and the second adjacent area base are disposedat a same height as the first pocket base. In some embodiments, at leastone of the first adjacent area base and the second adjacent area baseare disposed at a reduced height compared to the first pocket base. Insome embodiments, the epoxy forms a downward-inflecting meniscus at theat least one of the first and second transitions. In some embodiments,the epoxy adheres to the at least one of the first and secondtransitions and inhibits the epoxy from creeping into the at least oneof the first and second transitions.

According to some embodiments, an analyte sensing apparatus includes ahousing including an aperture that defines a cavity in the housing, thecavity having a first portion and a second portion. The apparatusincludes a first heat-sealable thermoplastic elastomer disposed along aperimeter of the first portion of the cavity. The apparatus includes ananalyte sensor having at least a portion disposed within the firstportion of the cavity. The apparatus includes a cap configured to fit onor within the aperture and over the first portion of the cavity. The capincludes a second heat-sealable thermoplastic elastomer along at least aportion of the cap disposed over a border between the first and secondportions of the cavity. The first and second heat-sealable thermoplasticelastomers are configured to seal the first portion of the cavity frommoisture ingress upon being melted. In some embodiments, the borderbetween the first and second portions of the cavity includes a portionof the first heat-sealable thermoplastic elastomer.

According to some embodiments, an analyte sensing apparatus includes ahousing including a cavity in the housing, a first conductive contact, asecond conductive contact, and a cap configured to fit on or within theaperture. The analyte sensor includes an elongated body, a firstelectrode in physical contact with the first conductive contact, and asecond electrode in physical contact with the second conductive contact.The cap includes a base, and a sealing material configured to at leastpartially fill the cavity. The sealing member includes a first cavityconfigured to align over the first electrode and the first conductivecontact and a second cavity configured to align over the secondelectrode and the second conductive contact.

In some embodiments, the first cavity contains a first conductiveelastomeric puck and the second cavity contains a second conductiveelastomeric puck. In some embodiments, the first conductive elastomericpuck is configured to press against the first electrode and the firstconductive contact, and the second conductive elastomeric puck isconfigured to press against the second electrode and the secondconductive contact. In some embodiments, the first conductiveelastomeric puck secures the first electrode to the first conductivecontact and the second conductive elastomeric puck secures the secondelectrode to the second conductive contact. In some embodiments, thefirst conductive elastomeric puck is configured to press against thefirst electrode and the cap, and the second conductive elastomeric puckis configured to press against the second electrode and the secondconductive contact. In some embodiments, the first and second conductiveelastomeric pucks have a substantially cylindrical shape. In someembodiments, the first conductive contact has a gap formed within. Insome embodiments, the first conductive elastomeric puck is disposedwithin the gap of the first conductive contact. In some embodiments, thefirst conductive elastomeric puck is disposed within the gap of thefirst conductive contact by press fit. In some embodiments, the firstcavity is configured to retain a first injection of conductive epoxyconfigured to electrically couple the first electrode and the firstconductive contact. In some embodiments, the second cavity is configuredto retain a second injection of conductive epoxy configured toelectrically couple the second electrode and the second conductivecontact. In some embodiments, the first and second cavities have asubstantially conical shape. In some embodiments, the base of the capfurther includes at least a first hole that aligns laterally with thefirst cavity and a second hole that aligns laterally with the secondcavity, at least a portion of the sealing material physically isolatingthe first hole from the first cavity and the second hole from the secondcavity.

According to some embodiments, a method for fabricating an analytesensing apparatus includes forming a housing including an aperture thatdefines a cavity having a first portion and a second portion in thehousing. The method includes disposing a first conductive contact and asecond conductive contact in the first portion of the cavity. The methodincludes electrically coupling a first electrode of an analyte sensor tothe first conductive contact. The method includes electrically couplinga second electrode of the analyte sensor to the second conductivecontact. The method includes forming a cap having a first portion and asecond portion, a dam disposed on a side of the cap configured to facethe aperture, a shelf adjacent to the dam, and a compliant componentdisposed on the shelf. The method includes fitting the cap on or withinthe aperture such that the first portion of the cap is disposed over thefirst portion of the cavity, the dam physically divides the firstportion of the cavity from the second portion of the cavity, and thecompliant component presses against a portion of the analyte sensor andagainst a surface of the housing within the cavity, thereby sealing thefirst portion of the cavity from the second portion of the cavity.

In some embodiments, the method includes disposing an electronicsassembly substrate within the housing, wherein the first conductivecontact and the second conductive contact extend from the electronicsassembly substrate into the first portion of the cavity. In someembodiments, the first portion of the cap includes a first hole, themethod further including depositing an encapsulating sealant into thefirst portion of the cavity through the first hole, thereby sealing atleast a portion of the analyte sensor from moisture ingress. In someembodiments, the first portion of the cap includes a second hole, themethod further including allowing excess encapsulating sealant to flowout of the first portion of the cavity through the second hole. In someembodiments, the compliant component prevents the encapsulating sealantfrom flowing into the second portion of the cavity. In some embodiments,the cap includes a second portion disposed over the second portion ofthe cavity. In some embodiments, the second portion of the cap includesa slot, the method further including causing at least a portion of theanalyte sensor to pass through the slot. In some embodiments, anoutside-facing surface of the cap fits flush with an outside-facingsurface of the housing. In some embodiments, an outside-facing surfaceof the cap fits in a recessed position compared to an outside-facingsurface of the housing. In some embodiments, the cap is disposed on anoutside-facing surface of the housing. In some embodiments, the methodincludes securing the cap to the housing utilizing at least one of a toefeature, a snap feature, a friction-fit feature, and apressure-sensitive adhesive. In some embodiments, the first portion ofthe cap and the second portion of the cap are coplanar and formed of asingle piece. In some embodiments, the cap includes a materialsubstantially transparent to ultra-violet radiation, the method furtherincluding curing the encapsulating sealant by exposing the encapsulatingsealant to the ultra-violet radiation through the cap. In someembodiments, the dam contacts a portion of the housing within thecavity. In some embodiments, the compliant material includes a foam or arubber material.

In some embodiments, the method includes securing the cap to the housingutilizing a first adhesive portion of an adhesive patch, the adhesivepatch further including a second adhesive portion configured to adherethe first adhesive portion and the wearable assembly to a skin of ahost. In some embodiments, the method includes securing the firstadhesive portion of the adhesive patch to the cap before the cap is fiton or within the aperture of the housing. In some embodiments, the firstadhesive portion includes at least one hole configured to substantiallycoincide with at least one hole within the cap when the cap is securedto the first adhesive portion of the adhesive patch. In someembodiments, the second adhesive portion includes at least one holeconfigured to substantially coincide with at least one hole within thecap when the cap is secured to the second adhesive portion of theadhesive patch.

In some embodiments, a second portion of the cap is disposed adjacent tothe second portion of the cavity. In some embodiments, the first portionof the cap extends along a first plane, the second portion of the capextends along a second plane different from the first plane, the damincludes at least a portion of the cap that extends between the firstplane and the second plane and connects the first portion of the capwith the second portion of the cap, and at least some of the secondportion of the cap includes the shelf.

In some embodiments, the method includes depositing at least onepassivation layer over at least a portion of the first portion of thecavity and over at least a portion of the analyte sensor, therebypreventing moisture ingress to the portion of the sensor. In someembodiments, the method includes depositing one or more conductivetraces on the at least one passivation layer and electrically couplingthe one or more conductive traces to one or more of the first conductivecontact and the second conductive contact.

According to some embodiments, a method of fabricating an analytesensing apparatus includes fabricating a housing, disposing anelectronics assembly substrate within the housing, and coupling ananalyte sensor including an elongated body having at least a first bendto at least one of the housing and the electronics assembly substrate.

In some embodiments, the method includes forming the first bend in theanalyte sensor such that a portion of the elongated body distal of thefirst bend extends substantially parallel to a plane of the electronicsassembly substrate and a portion of the elongated body proximal to thefirst bend extends substantially perpendicular to the plane of theelectronics assembly substrate and at least partially into theelectronics assembly substrate. In some embodiments, the housingincludes a recess, the method further including extending at least someof the portion of the elongated body proximal to the first bend throughthe electronics assembly substrate and into the recess. In someembodiments, the portion of the elongated body proximal to the firstbend exerts a biasing force against a portion of the electronicsassembly substrate, thereby securing the analyte sensor in a desiredorientation with respect to the electronics assembly substrate.

In some embodiments, the method includes forming the first bend in theanalyte sensor such that a portion of the elongated body distal of thefirst bend extends substantially parallel to a plane of the electronicsassembly substrate and a portion of the elongated body proximal to thefirst bend extends substantially perpendicular to the plane of theelectronics assembly substrate and away from the electronics assemblysubstrate. In some embodiments, the housing further includes a recess ina sidewall of the housing, the method further including extending atleast some of the portion of the elongated body proximal to the firstbend within the recess, thereby restraining the analyte sensor in adesired orientation with respect to the electronics assembly substrate.In some embodiments, the portion of the elongated body proximal to thefirst bend exerts a biasing force against a portion of the housing,thereby securing the analyte sensor in a desired orientation withrespect to the electronics assembly substrate. In some embodiments, themethod includes forming at least one additional bend in the analytesensor proximal to the first bend such that the at least one additionalbend causes at least a first part of the elongated body proximal to thefirst bend and distal to the at least one additional bend to extend in afirst direction within the recess and exert a first biasing force at afirst location along the recess, and at least a second part of theelongated body proximal to the first bend and proximal to the at leastone additional bend to extend in a second direction within the recessand exert a second biasing force at a second location along the recess,thereby securing the analyte sensor in a desired orientation withrespect to the electronics assembly substrate.

In some embodiments, the method includes forming the first bend in theanalyte sensor such that a portion of the elongated body distal of thefirst bend extends in a first direction substantially parallel to aplane of the electronics assembly substrate and a portion of theelongated body proximal to the first bend extends in a second directionthat is different from the first direction but also substantiallyparallel to the plane of the electronics assembly substrate. In someembodiments, the method includes forming at least one additional bend inthe analyte sensor proximal to the first bend such that the at least oneadditional bend causes at least a first part of the elongated bodyproximal to the first bend and distal to the at least one additionalbend to extend in the second direction and exert a first biasing forceat a first location along one of the housing and the electronicsassembly substrate, and at least a second part of the elongated bodyproximal to the first bend and proximal to the at least one additionalbend to extend in a third direction substantially parallel to the planeof the electronics assembly substrate and exert a second biasing forceat a second location along one of the housing and the electronicsassembly substrate, thereby securing the analyte sensor in a desiredorientation with respect to the electronics assembly substrate.

In some embodiments, the electronic assembly substrate includes a postand the method includes forming the first bend in the analyte sensorsuch that a portion of the elongated body distal of the first bendextends in a first direction substantially parallel to a plane of theelectronics assembly substrate and a portion of the elongated bodyproximal to the first bend extends substantially along a perimeter ofthe post, thereby securing the analyte sensor in a desired orientationwith respect to the electronics assembly substrate. In some embodiments,the portion of the elongated body distal of the first bend exerts afirst biasing force at a first location along one of the housing and theelectronics assembly substrate, thereby securing the analyte sensor in adesired orientation with respect to the electronics assembly substrate.In some embodiments, the first bend exerts a second biasing force at asecond location along one of the housing and the electronics assemblysubstrate, thereby further securing the analyte sensor in the desiredorientation. In some embodiments, wherein the portion of the elongatedbody proximal of the first bend exerts a third biasing force at a thirdlocation along one of the housing and the electronics assemblysubstrate, thereby further securing the analyte sensor in the desiredorientation. In some embodiments, the second biasing force is exerted ina substantially opposite direction from the third biasing force. In someembodiments, the first biasing force is exerted in a substantiallyperpendicular direction to each of the second biasing force and thethird biasing force. In some embodiments, the first bend provides afirst torque about the first bend that pushes the portion of theelongated body distal of the first bend against the first location. Insome embodiments, the first bend provides a second torque about thefirst bend that pushes the portion of the elongated body proximal of thefirst bend against the third location.

According to some embodiments a method of fabricating an analyte sensingapparatus is provided. The method includes forming a housing including acavity having a first portion and a second portion. The method includesforming a first dam in the first portion of the cavity adjacent to afirst side of the first conductive contact. The method includes forminga second dam in the first portion of the cavity adjacent to a secondside of the first conductive contact opposite the first side, the firstdam and the second dam defining a first well encompassing the firstconductive contact. The method includes disposing an analyte sensor onthe first dam and on the second dam. The method includes coupling afirst electrode of the analyte sensor to the first conductive contact.The method includes coupling a second electrode of the analyte sensor tothe second conductive contact.

In some embodiments, the method includes disposing an electronicsassembly substrate within the housing, wherein the first and secondconductive contacts extend from the electronics assembly substrate intothe first portion of the cavity. In some embodiments, the first dam andthe second dam each include a sloped cross-section, the analyte sensorresting on a lowest point of the sloped cross-section of the first damand on a lowest point of the sloped cross-section of the second dam. Insome embodiments, the sloped cross-sections of the first and second damsare one of triangularly-recessed, parabolically-recessed,semi-circularly-recessed or hyperbolically-recessed cross-sections. Insome embodiments, the method includes disposing conductive epoxy over atleast a portion of the first conductive contact within the first well.In some embodiments, the conductive epoxy is disposed at least to aheight of the lowest point of the sloped cross-section of the first damor of the lowest point of the sloped cross-section of the second damsuch that the first electrode of the analyte sensor is in directphysical and electrical contact with the conductive epoxy when disposedon the first dam and on the second dam.

According to some embodiments, a method of fabricating an analytesensing apparatus housing is provided. The method includes forming afirst pocket having a first pocket base in the housing. The methodincludes forming a first adjacent area in the housing abutting a firstside of the first pocket, the first adjacent area having a firstadjacent area base and a first transition between the first pocket baseand the first adjacent area base. The method includes forming a secondadjacent area in the housing abutting a second side of the first pocket,the second adjacent area having a second adjacent area base and a secondtransition between the first pocket base and the second adjacent areabase.

In some embodiments, the method includes disposing an electronicsassembly substrate within the housing. In some embodiments, the firstpocket has a substantially rectangular-shaped geometry such thatsidewalls of the first pocket are substantially planar and meet oneanother to form angled corners. In some embodiments, the first pockethas a substantially rounded rectangular-shaped geometry such thatportions of sidewalls of the first pocket are substantially planar whileother portions of the sidewalls that connect the substantially planarportions are curved. In some embodiments, the first pocket has asubstantially diamond-shaped geometry such that sidewalls of the firstpocket are substantially planar and meet one another to form angledcorners. In some embodiments, the first pocket has a substantiallyrounded diamond-shaped geometry such that portions of sidewalls of thefirst pocket are substantially planar while other portions of thesidewalls that connect the substantially planar portions are curved. Insome embodiments, the first pocket has a substantially polygonal-shapedgeometry such that sidewalls of the first pocket are substantiallyplanar and meet one another to form angled corners. In some embodiments,the first pocket has a substantially rounded polygonal-shaped geometrysuch that portions of sidewalls of the first pocket are substantiallyplanar while other portions of the sidewalls that connect thesubstantially planar portions are curved. In some embodiments, at leastone of the first adjacent area base and the second adjacent area baseare disposed at an elevated height compared to the first pocket basesuch that at least one of the first transition and the second transitionstep up from the first pocket base. In some embodiments, the elevatedheight is approximately 0.5 millimeters. In some embodiments, the methodincludes depositing epoxy on the pocket base, wherein the epoxy forms anupward-inflecting meniscus at the at least one of the first and secondtransitions and the elevated height exceeds a height of theupward-inflecting meniscus. In some embodiments, the elevated height isa function of the first predetermined amount and at least one of aviscosity, a surface energy and a surface tension characteristic of theepoxy. In some embodiments, at least one of the first adjacent area baseand the second adjacent area base are disposed at a same height as thefirst pocket base. In some embodiments, at least one of the firsttransition and the second transition are flush with the first pocketbase. In some embodiments, the method includes depositing epoxy on thepocket base, wherein at least one of the first adjacent area base andthe second adjacent area base are disposed at a lower height compared tothe first pocket base. In some embodiments, the elevated height is afunction of the first predetermined amount and at least one of aviscosity, a surface energy and a surface tension characteristic of theepoxy. In some embodiments, at least one of the first adjacent area baseand the second adjacent area base are disposed at a same height as thefirst pocket base. In some embodiments, at least one of the firsttransition and the second transition are flush with the first pocketbase. In some embodiments, the method includes depositing epoxy on thepocket base, wherein at least one of the first adjacent area base andthe second adjacent area base are disposed at a lower height compared tothe first pocket base. In some embodiments, at least one of the firsttransition and the second transition step down from the first pocketbase. In some embodiments, the lower height is approximately 0.5millimeters. In some embodiments, the epoxy forms a downward-inflectingmeniscus at the at least one of the first and second transitions. Insome embodiments, the epoxy adheres to the at least one of the first andsecond transitions and inhibits the epoxy from creeping into the atleast one of the first and second transitions. In some embodiments, oneof the first adjacent area base and the second adjacent area base isdisposed at a lower height compared to the first pocket base and theother of the first adjacent area base and the second adjacent area baseis disposed at an elevated height compared to the first pocket base. Insome embodiments, both of the first adjacent area base and the secondadjacent area base is disposed at a lower height compared to the firstpocket base. In some embodiments, the first adjacent area has any of asubstantially rectangular-shaped geometry, a substantially roundedrectangular-shaped geometry, a substantially diamond-shaped geometry, asubstantially rounded diamond-shaped geometry, a substantiallypolygonal-shaped geometry, a substantially rounded polygonal-shapedgeometry, and a substantially irregular-shaped geometry. In someembodiments, the second adjacent area has any of a substantiallyrectangular-shaped geometry, a substantially rounded rectangular-shapedgeometry, a substantially diamond-shaped geometry, a substantiallyrounded diamond-shaped geometry, a substantially polygonal-shapedgeometry, a substantially rounded polygonal-shaped geometry, and asubstantially irregular-shaped geometry. In some embodiments, sidewallsof the first pocket are disposed substantially perpendicular to thefirst pocket base. In some embodiments, sidewalls of the first pocketare disposed at an angle from substantially perpendicular to the firstpocket base. In some embodiments, sidewalls of at least one of the firstand second adjacent areas are disposed substantially perpendicular tothe respective first and second adjacent area bases. In someembodiments, sidewalls of at least one of the first and second adjacentareas are disposed at an angle from substantially perpendicular to therespective first and second adjacent area bases. In some embodiments,sidewalls of at least one of the first and second transitions aredisposed substantially perpendicular to the first pocket base. In someembodiments, sidewalls of at least one of the first and secondtransitions are disposed at an angle from substantially perpendicular tothe first pocket base. In some embodiments, sidewalls of at least one ofthe first and second transitions are rounded such that angled cornersare not formed at the at least one of the first and second transitions.In some embodiments, a first width of the first transition and a secondwidth of the second transition are substantially within the range of 0.5mm and 2.0 mm. In some embodiments, a first width of the firsttransition is greater than a second width of the second transition. Insome embodiments, a first width of the first transition is less than asecond width of the second transition. In some embodiments, the methodincludes disposing a conductive contact in the first adjacent area or inthe second adjacent area. In some embodiments, the method includesdisposing an analyte sensor having a first electrode and a secondelectrode on the housing and electrically connecting one of the firstelectrode and the second electrode with the conductive contact.

In some embodiments, the method includes disposing a post in the firstadjacent area or in the second adjacent area, disposing epoxy on thepost, and disposing a portion of the analyte sensor in the epoxydisposed on the post. In some embodiments, the epoxy exerts a centeringforce on the portion of the analyte sensor disposed therein such thatthe analyte sensor is aligned substantially along a centerline of thepost. In some embodiments, the post has a substantially symmetricalgeometry about a centerline of the post.

In some embodiments, the method includes forming the pocket base with afirst surface energy and forming the first adjacent area base with asecond surface energy different from the first surface energy. In someembodiments, the method includes forming the second adjacent area basewith one of the second surface energy and a third surface energydifferent from the first and second surface energies.

In some embodiments, the method includes forming a third adjacent areaabutting the first pocket, the third adjacent area having a thirdadjacent area base disposed at a lower elevation than a top surface of asidewall of the first pocket and a third transition between the topsurface of the sidewall of the first pocket and the third adjacent areabase. In some embodiments, epoxy disposed within the first pocketadheres to the third transition and inhibits the epoxy from creepinginto the third adjacent area. In some embodiments, the third adjacentarea is configured to accept at least an excess portion of epoxydisposed within the first pocket, thereby preventing the epoxy fromcreeping into at least one of the first and second adjacent areas.

According to some embodiments, a method of fabricating an analytesensing apparatus is provided. The method includes forming a housing.The housing includes a first pocket having a first pocket base, a firstadjacent area abutting a first side of the first pocket, the firstadjacent area having a first adjacent area base and a first transitionbetween the first pocket base and the first adjacent area base, a secondadjacent area abutting a second side of the first pocket, the secondadjacent area having a second adjacent area base and a second transitionbetween the first pocket base and the second adjacent area base, and aconductive contact disposed in the first adjacent area or in the secondadjacent area. The method includes disposing an electronics assemblysubstrate within the housing and electrically coupling the electronicsassembly substrate to the conductive contact. The method includesdisposing an analyte sensor including at least one electrode inelectrical communication with the conductive contact. The methodincludes disposing epoxy on the first pocket base, the epoxy securing atleast a portion of the analyte sensor to the first pocket base.

In some embodiments, at least one of the first adjacent area base andthe second adjacent area base are disposed at an elevated heightcompared to the first pocket base. In some embodiments, the epoxy formsan upward-inflecting meniscus at the at least one of the first andsecond transitions and the elevated height exceeds a height of theupward-inflecting meniscus. In some embodiments, at least one of thefirst adjacent area base and the second adjacent area base are disposedat a same height as the first pocket base. In some embodiments, at leastone of the first adjacent area base and the second adjacent area baseare disposed at a reduced height compared to the first pocket base. Insome embodiments, the epoxy forms a downward-inflecting meniscus at theat least one of the first and second transitions. In some embodiments,the epoxy adheres to the at least one of the first and secondtransitions and inhibits the epoxy from creeping into the at least oneof the first and second transitions.

According to some embodiments, a method of fabricating an analytesensing apparatus is provided. The method includes forming a housingincluding an aperture that defines a cavity having a first portion and asecond portion in the housing. The method includes disposing a firstheat-sealable thermoplastic elastomer along a perimeter of the firstportion of the cavity. The method includes disposing at least a portionof an analyte sensor within the first portion of the cavity. The methodincludes fitting a cap on or within the aperture and over the firstportion of the cavity, the cap including a second heat-sealablethermoplastic elastomer along at least a portion of the cap disposedover a border between the first and second portions of the cavity. Themethod includes melting the first and second heat-sealable thermoplasticelastomers, thereby sealing the first portion of the cavity frommoisture ingress.

In some embodiments, the border between the first and second portions ofthe cavity includes a portion of the first heat-sealable thermoplasticelastomer.

According to some embodiments, a method of fabricating an analytesensing apparatus is provided. The method includes forming a housingincluding an aperture that defines a housing cavity in the housing. Themethod includes disposing a first conductive contact and a secondconductive contact in the housing cavity. The method includes placing afirst electrode of an analyte sensor on the first conductive contact.The method includes placing a second electrode of the analyte sensor onthe second conductive contact. The method includes providing a cap. Thecap includes a base and a sealing material including a first cavity anda second cavity. The method includes fitting the cap on or within theaperture such that the sealing material at least partially fill a voidwithin the housing cavity and presses against the housing, the firstcavity aligns over the first electrode and the first conductive contact,and the second cavity aligns over the second electrode and the secondconductive contact.

In some embodiments, the method includes, before fitting the cap on orwithin the aperture, disposing a first conductive elastomeric puck inthe first cavity, and disposing a second conductive elastomeric puck inthe second cavity. The first conductive elastomeric puck is configuredto press against the first electrode and the first conductive contactwhen the cap is fitted on or within the aperture, thereby securing thefirst electrode to the first conductive contact. The second conductiveelastomeric puck is configured to press against the second electrode andthe second conductive contact when the cap is fitted on or within theaperture, thereby securing the second electrode to the second conductivecontact.

In some embodiments, the first and second conductive elastomeric puckshave a substantially cylindrical shape. In some embodiments, the base ofthe cap further includes at least a first hole that aligns laterallywith the first cavity and a second hole that aligns laterally with thesecond cavity, at least a portion of the sealing material physicallyisolating the first hole from the first cavity and the second hole fromthe second cavity. In some embodiments, the method includes injectingconductive epoxy into the first cavity through the first hole andthrough the portion of the sealing material, thereby electricallyconnecting the first electrode to the first conductive contact andinjecting conductive adhesive into the second cavity through the secondhole and through the portion of the sealing material, therebyelectrically connecting the second electrode to the second conductivecontact. In some embodiments, the first and second cavities have asubstantially conical shape.

It is understood that various configurations of the subject technologywill become readily apparent to those skilled in the art from thedisclosure, wherein various configurations of the subject technology areshown and described by way of illustration. As will be realized, thesubject technology is capable of other and different configurations andits several details are capable of modification in various otherrespects, all without departing from the scope of the subjecttechnology. Accordingly, the summary, drawings and detailed descriptionare to be regarded as illustrative in nature and not as restrictive.

BRIEF DESCRIPTION OF THE DRAWINGS

The present embodiments now will be discussed in detail with an emphasison highlighting the advantageous features. These embodiments are forillustrative purposes only and are not to scale, instead emphasizing theprinciples of the disclosure. These drawings include the followingfigures, in which like numerals indicate like parts:

FIG. 1 is a schematic view of an analyte sensor system attached to ahost and communicating with a plurality of example devices, according tosome embodiments;

FIG. 2 is a block diagram that illustrates electronics associated withthe sensor system of FIG. 1, according to some embodiments;

FIGS. 3A-3C illustrate a wearable device having an analyte sensor,according to some embodiments;

FIG. 3D illustrates one implementation of an elongated sensor connectedto a potentiostat;

FIG. 4A illustrates a schematic of a pre-connected analyte sensor,according to some embodiments;

FIG. 4B illustrates another schematic of a pre-connected analyte sensor,according to some embodiments;

FIG. 4C illustrates a layered view of a pre-connected analyte sensor,according to some embodiments;

FIG. 4D illustrates a schematic view of an array of pre-connectedanalyte sensors, according to some embodiments;

FIGS. 5A-5B illustrate perspective views of a wearable sensor assembly,according to some embodiments;

FIG. 5C illustrates an exploded view of components of a wearable sensorassembly, according to some embodiments;

FIG. 6A shows a perspective view of an embodiment of a wearable assemblyhaving a sensor directly connected to an electronics assembly substrateon which sensor electronics are disposed, according to some embodiments;

FIG. 6B shows a plan view of the bottom of the wearable assembly of FIG.6A, according to some embodiments;

FIG. 6C shows a side cutaway view of the wearable assembly of FIG. 6A,according to some embodiments;

FIG. 7A illustrates a perspective view of a cap for sealing an aperturewithin a housing of a wearable assembly, according to some embodiments;

FIG. 7B illustrates another perspective view of the cap of FIG. 7A,according to some embodiments;

FIG. 7C illustrates a perspective view of the cap of FIGS. 7A and 7Bdisposed over an aperture within the housing of the wearable assembly,according to some embodiments;

FIG. 7D illustrates a perspective view of the cap of FIGS. 7A-7Cdisposed flush or slightly recessed within the aperture of the housing,according to some embodiments;

FIG. 8A illustrates a plan view of a two-part patch for securing awearable assembly to the skin of a host, according to some embodiments;

FIG. 8B illustrates a plan view of a cap, such as the caps described inconnection with FIGS. 7A-7D, 9 and/or 10, coupled to a patch forsecuring a wearable assembly to the skin of the host, according to someembodiments;

FIG. 8C illustrates a plan view of a patch configured to act as a cap,similar to the caps described in connection with FIGS. 7A-7D, 9 and/or10, and for securing a wearable assembly to the skin of the host,according to some embodiments;

FIG. 8D illustrates a plan view of a portion of the patch of FIG. 8Aconfigured to adhere the patch a cap, such as the caps described inconnection with FIGS. 7A-7D, 9 and/or 10, and a wearable assembly to theskin of the host, according to some embodiments;

FIG. 9 illustrates a side cutaway view of a cap for sealing an aperturewithin a housing of a wearable assembly, according to some embodiments;

FIG. 10 illustrates a perspective view of a cap comprising apre-connected sensor and configured to seal an aperture within a housingof a wearable assembly, according to some embodiments;

FIG. 11A illustrates side and top views of a first type of sensor bend,according to some embodiments;

FIG. 11B illustrates side and top views of a second type of sensor bend,according to some embodiments;

FIG. 11C illustrates side and top views of a third type of sensor bend,according to some embodiments;

FIG. 12 illustrates a side cutaway view of an example of the first typeof sensor bend of FIG. 11A, according to some embodiments;

FIG. 13 illustrates a side cutaway view of another example of the firsttype of sensor bend of FIG. 11A, according to some embodiments;

FIG. 14A illustrates a plan view of an example of the second type ofsensor bend of FIG. 11B, according to some embodiments;

FIG. 14B illustrates a side cutaway view of the example of FIG. 14A;

FIG. 15 illustrates a side cutaway view of another example of the secondtype of sensor bend of FIG. 11B, according to some embodiments;

FIG. 16A illustrates a first side cutaway view of yet another example ofthe second type of sensor bend of FIG. 11B, according to someembodiments;

FIG. 16B illustrates a second side cutaway view of FIG. 16A as viewedalong the cut line B-B′, according to some embodiments.

FIG. 17 illustrates a plan view of an example of the third type ofsensor bend of FIG. 11C, according to some embodiments;

FIG. 18 illustrates a plan view of another example of the third type ofsensor bend of FIG. 11C, according to some embodiments;

FIG. 19 illustrates a plan view of yet another example of the third typeof sensor bend of FIG. 11C, according to some embodiments;

FIG. 20 illustrates a plan view of yet another example of the third typeof sensor bend of FIG. 11C, according to some embodiments;

FIG. 21A illustrates a top view of a portion of a wearable assemblycomprising a plurality of dams that form a plurality of wells forcontaining and preventing undesirable bleeding or migration of epoxy,according to some embodiments;

FIG. 21B illustrates a side cutaway view of the portion of the wearableassembly of FIG. 21A viewed along the cut line A-A′, according to someembodiments;

FIG. 21C illustrates another side cutaway view of the portion of thewearable assembly of FIG. 21A viewed along the cut line B-B′, accordingto some embodiments;

FIG. 21D illustrates another side cutaway view of the portion of thewearable assembly of FIG. 21A viewed along the cut line C-C′, accordingto some embodiments;

FIG. 22 illustrates a perspective view of a plurality of pockets havingvarying geometries for securing a sensor utilizing epoxy, in combinationwith step-up, step-down or flush transitions of varying widths forpreventing the epoxy from bleeding to adjacent areas, according to someembodiments;

FIG. 23 illustrates a plan view of several example geometries for thepockets of FIG. 22, according to some embodiments;

FIG. 24 illustrates a set of side views of an example step-up transitionas would be viewed along the cut-lines A-A′ in FIG. 22, an example flushtransition as would be viewed along

DEXCOM.439C2 PATENT the cut-line B-B′ in FIG. 22, and an examplestep-down transition as would be viewed along the cut-line C-C′ in FIG.22, according to some embodiments;

FIG. 25 illustrates another set of side views of the transitions of FIG.24 as viewed along the cut-lines A-A′, B-B′ and C-C′ in FIG. 24,according to some embodiments;

FIG. 26 illustrates a photograph of a top view of example first andsecond arrangements of epoxied pockets in combination with step-up andstep-down transitions to adjacent areas, according to some embodiments;

FIG. 27 illustrates a plan view and a side cutaway view of anarrangement utilizing pockets and adjacent areas similar to thosedescribed in connection with FIGS. 22-26 for securing a sensor directlyto an electronics substrate assembly, further utilizing a post forcentering the sensor, according to some embodiments;

FIG. 28A illustrates a perspective view of a wearable assembly having asensor directly connected to an electronics assembly substrate,according to some embodiments;

FIG. 28B illustrates an exploded perspective view of the wearableassembly of FIG. 28A further including a passivation layer depositedover at least a portion of the electronics assembly substrate and thesensor;

FIG. 28C illustrates an exploded perspective view of the wearableassembly of FIG. 28B further including an encapsulating sealant disposedover the passivation layer;

FIG. 29 illustrates a side cutaway view of a wearable assemblycomprising an electronics assembly substrate having a plurality ofpassivation layers and conductive trace layers serially depositedthereon, according to some embodiments;

FIG. 30A illustrates a plan view of a wearable assembly having aheat-sealable thermoplastic elastomer and a mating cap having theheat-sealable thermoplastic elastomer, according to some embodiments;

FIG. 30B illustrates a side cutaway view of the wearable assembly ofFIG. 30A, as viewed along the cutline A-A′ and the mating cap disposedfor securing to wearable assembly, according to some embodiments;

FIG. 31 illustrates a side cutaway view of a wearable assembly and anovermolded cap, according to some embodiments;

FIG. 32 illustrates a side cutaway view of a wearable assembly andanother overmolded cap, according to some embodiments;

FIG. 33 illustrates a flow chart of illustrative operations that may beperformed for manufacturing and using an analyte sensor directlyconnected to a circuit board of a transmitter, according to someembodiments;

FIG. 34 illustrates another flow chart of illustrative operations thatmay be performed for manufacturing and using an analyte sensor directlyconnected to a circuit board of a transmitter, according to someembodiments;

FIG. 35 illustrates another flow chart of illustrative operations thatmay be performed for manufacturing and using an analyte sensor directlyconnected to a circuit board of a transmitter, according to someembodiments;

FIG. 36 illustrates another flow chart of illustrative operations thatmay be performed for manufacturing and using an analyte sensor directlyconnected to a circuit board of a transmitter, according to someembodiments;

FIG. 37 illustrates another flow chart of illustrative operations thatmay be performed for manufacturing and using an analyte sensor directlyconnected to a circuit board of a transmitter, according to someembodiments;

FIG. 38 illustrates another flow chart of illustrative operations thatmay be performed for manufacturing and using an analyte sensor directlyconnected to a circuit board of a transmitter, according to someembodiments;

FIG. 39 illustrates another flow chart of illustrative operations thatmay be performed for manufacturing and using an analyte sensor directlyconnected to a circuit board of a transmitter, according to someembodiments;

FIG. 40A illustrates a perspective view of a pocket and step-downtransitions to adjacent areas having different surface energies than thepocket for preventing the epoxy from bleeding to adjacent areas,according to some embodiments;

FIG. 40B illustrates a perspective view of a pocket and flushtransitions to adjacent areas having different surface energies than thepocket for preventing the epoxy from bleeding to adjacent areas,according to some embodiments; and

FIG. 41 illustrates a side cutaway view of a pocket having step-downtransitions to adjacent areas, and further including an additionalstep-down transition to an additional adjacent area for preventing theepoxy from bleeding to adjacent areas, according to some embodiments.

Like reference numerals refer to like elements throughout. Elements arenot to scale unless otherwise noted.

DETAILED DESCRIPTION

The following description and examples illustrate some exemplaryimplementations, embodiments, and arrangements of the disclosedinvention in detail. Those of skill in the art will recognize that thereare numerous variations and modifications of this invention that areencompassed by its scope. Accordingly, the description of a certainexample embodiment should not be deemed to limit the scope of thepresent invention.

Definitions

In order to facilitate an understanding of the various embodimentsdescribed herein, a number of terms are defined below.

The term “analyte” as used herein is a broad term and is to be given itsordinary and customary meaning to a person of ordinary skill in the art(and is not to be limited to a special or customized meaning), andfurthermore refers without limitation to a substance or chemicalconstituent in a biological fluid (for example, blood, interstitialfluid, cerebral spinal fluid, lymph fluid or urine) that can beanalyzed. Analytes can include naturally occurring substances,artificial substances, metabolites, and/or reaction products. In someembodiments, the analyte for measurement by the sensor heads, devices,and methods is analyte. However, other analytes are contemplated aswell, including but not limited to acarboxyprothrombin; acylcarnitine;adenine phosphoribosyl transferase; adenosine deaminase; albumin;alpha-fetoprotein; amino acid profiles (arginine (Krebs cycle),histidine/urocanic acid, homocysteine, phenylalanine/tyrosine,tryptophan); andrenostenedione; antipyrine; arabinitol enantiomers;arginase; benzoylecgonine (cocaine); biotinidase; biopterin; c-reactiveprotein; carnitine; carnosinase; CD4; ceruloplasmin; chenodeoxycholicacid; chloroquine; cholesterol; cholinesterase; conjugated 1-βhydroxy-cholic acid; cortisol; creatine kinase; creatine kinase MMisoenzyme; cyclosporin A; D-penicillamine; de-ethylchloroquine;dehydroepiandrosterone sulfate; DNA (acetylator polymorphism, alcoholdehydrogenase, alpha 1-antitrypsin, cystic fibrosis, Duchenne/Beckermuscular dystrophy, analyte-6-phosphate dehydrogenase, hemoglobin A,hemoglobin S, hemoglobin C, hemoglobin D, hemoglobin E, hemoglobin F,D-Punjab, beta-thalassemia, hepatitis B virus, HCMV, HIV-1, HTLV-1,Leber hereditary optic neuropathy, MCAD, RNA, PKU, Plasmodium vivax,sexual differentiation, 21-deoxycortisol); desbutylhalofantrine;dihydropteridine reductase; diptheria/tetanus antitoxin; erythrocytearginase; erythrocyte protoporphyrin; esterase D; fattyacids/acylglycines; free β-human chorionic gonadotropin; freeerythrocyte porphyrin; free thyroxine (FT4); free tri-iodothyronine(FT3); fumarylacetoacetase; galactose/gal-1-phosphate;galactose-1-phosphate uridyltransferase; gentamicin; analyte-6-phosphatedehydrogenase; glutathione; glutathione perioxidase; glycocholic acid;glycosylated hemoglobin; halofantrine; hemoglobin variants;hexosaminidase A; human erythrocyte carbonic anhydrase I;17-alpha-hydroxyprogesterone; hypoxanthine phosphoribosyl transferase;immunoreactive trypsin; lactate; lead; lipoproteins ((a), B/A-1, β);lysozyme; mefloquine; netilmicin; phenobarbitone; phenytoin;phytanic/pristanic acid; progesterone; prolactin; prolidase; purinenucleoside phosphorylase; quinine; reverse tri-iodothyronine (rT3);selenium; serum pancreatic lipase; sissomicin; somatomedin C; specificantibodies (adenovirus, anti-nuclear antibody, anti-zeta antibody,arbovirus, Aujeszky's disease virus, dengue virus, Dracunculusmedinensis, Echinococcus granulosus, Entamoeba histolytica, enterovirus,Giardia duodenalisa, Helicobacter pylori, hepatitis B virus, herpesvirus, HIV-1, IgE (atopic disease), influenza virus, Leishmaniadonovani, leptospira, measles/mumps/rubella, Mycobacterium leprae,Mycoplasma pneumoniae, Myoglobin, Onchocerca volvulus, parainfluenzavirus, Plasmodium falciparum, poliovirus, Pseudomonas aeruginosa,respiratory syncytial virus, rickettsia (scrub typhus), Schistosomamansoni, Toxoplasma gondii, Trepenoma pallidium, Trypanosomacruzi/rangeli, vesicular stomatis virus, Wuchereria bancrofti, yellowfever virus); specific antigens (hepatitis B virus, HIV-1);succinylacetone; sulfadoxine; theophylline; thyrotropin (TSH); thyroxine(T4); thyroxine-binding globulin; trace elements; transferrin;UDP-galactose-4-epimerase; urea; uroporphyrinogen I synthase; vitamin A;white blood cells; and zinc protoporphyrin. Salts, sugar, protein, fat,vitamins, and hormones naturally occurring in blood or interstitialfluids can also constitute analytes in certain embodiments. The analytecan be naturally present in the biological fluid, for example, ametabolic product, a hormone, an antigen, an antibody, and the like.Alternatively, the analyte can be introduced into the body, for example,a contrast agent for imaging, a radioisotope, a chemical agent, afluorocarbon-based synthetic blood, or a drug or pharmaceuticalcomposition, including but not limited to insulin; ethanol; cannabis(marijuana, tetrahydrocannabinol, hashish); inhalants (nitrous oxide,amyl nitrite, butyl nitrite, chlorohydrocarbons, hydrocarbons); cocaine(crack cocaine); stimulants (amphetamines, methamphetamines, Ritalin,Cylert, Preludin, Didrex, PreState, Voranil, Sandrex, Plegine);depressants (barbituates, methaqualone, tranquilizers such as Valium,Librium, Miltown, Serax, Equanil, Tranxene); hallucinogens(phencyclidine, lysergic acid, mescaline, peyote, psilocybin); narcotics(heroin, codeine, morphine, opium, meperidine, Percocet, Percodan,Tussionex, Fentanyl, Darvon, Talwin, Lomotil); designer drugs (analogsof fentanyl, meperidine, amphetamines, methamphetamines, andphencyclidine, for example, Ecstasy); anabolic steroids; and nicotine.The metabolic products of drugs and pharmaceutical compositions are alsocontemplated analytes. Analytes such as neurochemicals and otherchemicals generated within the body can also be analyzed, such as, forexample, ascorbic acid, uric acid, dopamine, noradrenaline,3-methoxytyramine (3MT), 3,4-Dihydroxyphenylacetic acid (DOPAC),Homovanillic acid (HVA), 5-Hydroxytryptamine (5HT), and5-Hydroxyindoleacetic acid (FHIAA).

The terms “microprocessor” and “processor” as used herein are broadterms and are to be given their ordinary and customary meaning to aperson of ordinary skill in the art (and are not to be limited to aspecial or customized meaning), and furthermore refer without limitationto a computer system, state machine, and the like that performsarithmetic and logic operations using logic circuitry that responds toand processes the basic instructions that drive a computer.

The term “calibration” as used herein is a broad term and is to be givenits ordinary and customary meaning to a person of ordinary skill in theart (and is not to be limited to a special or customized meaning), andfurthermore refers without limitation to the process of determining therelationship between the sensor data and the corresponding referencedata, which can be used to convert sensor data into meaningful valuessubstantially equivalent to the reference data, with or withoututilizing reference data in real time. In some embodiments, namely, inanalyte sensors, calibration can be updated or recalibrated (at thefactory, in real time and/or retrospectively) over time as changes inthe relationship between the sensor data and reference data occur, forexample, due to changes in sensitivity, baseline, transport, metabolism,and the like.

The terms “calibrated data” and “calibrated data stream” as used hereinare broad terms and are to be given their ordinary and customary meaningto a person of ordinary skill in the art (and are not to be limited to aspecial or customized meaning), and furthermore refer without limitationto data that has been transformed from its raw state to another stateusing a function, for example a conversion function, including by use ofa sensitivity, to provide a meaningful value to a user.

The term “algorithm” as used herein is a broad term and is to be givenits ordinary and customary meaning to a person of ordinary skill in theart (and is not to be limited to a special or customized meaning), andfurthermore refers without limitation to a computational process (forexample, programs) involved in transforming information from one stateto another, for example, by using computer processing.

The term “sensor” as used herein is a broad term and is to be given itsordinary and customary meaning to a person of ordinary skill in the art(and is not to be limited to a special or customized meaning), andfurthermore refers without limitation to the component or region of adevice by which an analyte can be quantified. A “lot” of sensorsgenerally refers to a group of sensors that are manufactured on oraround the same day and using the same processes and tools/materials.Additionally, sensors that measure temperature, pressure etc. may bereferred to as a “sensor”.

The terms “glucose sensor” and “member for determining the amount ofglucose in a biological sample” as used herein are broad terms and areto be given their ordinary and customary meaning to a person of ordinaryskill in the art (and are not to be limited to a special or customizedmeaning), and furthermore refer without limitation to any mechanism(e.g., enzymatic or non-enzymatic) by which glucose can be quantified.For example, some embodiments utilize a membrane that contains glucoseoxidase that catalyzes the conversion of oxygen and glucose to hydrogenperoxide and gluconate, as illustrated by the following chemicalreaction:

Glucose+O₂→Gluconate+H₂O₂

Because for each glucose molecule metabolized, there is a proportionalchange in the co-reactant O₂ and the product H₂O₂, one can use anelectrode to monitor the current change in either the co-reactant or theproduct to determine glucose concentration.

The terms “operably connected” and “operably linked” as used herein arebroad terms and are to be given their ordinary and customary meaning toa person of ordinary skill in the art (and are not to be limited to aspecial or customized meaning), and furthermore refer without limitationto one or more components being linked to another component(s) in amanner that allows transmission of signals between the components. Forexample, one or more electrodes can be used to detect the amount ofglucose in a sample and convert that information into a signal, e.g., anelectrical or electromagnetic signal; the signal can then be transmittedto an electronic circuit. In this case, the electrode is “operablylinked” to the electronic circuitry. These terms are broad enough toinclude wireless connectivity.

The term “determining” encompasses a wide variety of actions. Forexample, “determining” may include calculating, computing, processing,deriving, investigating, looking up (e.g., looking up in a table, adatabase or another data structure), ascertaining and the like. Also,“determining” may include receiving (e.g., receiving information),accessing (e.g., accessing data in a memory) and the like. Also,“determining” may include resolving, selecting, choosing, calculating,deriving, establishing and/or the like. Determining may also includeascertaining that a parameter matches a predetermined criterion,including that a threshold has been met, passed, exceeded, and so on.

The term “substantially” as used herein is a broad term and is to begiven its ordinary and customary meaning to a person of ordinary skillin the art (and is not to be limited to a special or customizedmeaning), and furthermore refers without limitation to being largely butnot necessarily wholly that which is specified.

The term “host” as used herein is a broad term and is to be given itsordinary and customary meaning to a person of ordinary skill in the art(and is not to be limited to a special or customized meaning), andfurthermore refers without limitation to mammals, particularly humans.

The term “continuous analyte (or glucose) sensor” as used herein is abroad term and is to be given its ordinary and customary meaning to aperson of ordinary skill in the art (and is not to be limited to aspecial or customized meaning), and furthermore refers withoutlimitation to a device that continuously or continually measures aconcentration of an analyte, for example, at time intervals ranging fromfractions of a second up to, for example, 1, 2, or 5 minutes, or longer.In one exemplary embodiment, the continuous analyte sensor is a glucosesensor such as described in U.S. Pat. No. 6,001,067, which isincorporated herein by reference in its entirety.

The term “sensing membrane” as used herein is a broad term and is to begiven its ordinary and customary meaning to a person of ordinary skillin the art (and is not to be limited to a special or customizedmeaning), and furthermore refers without limitation to a permeable orsemi-permeable membrane that can be comprised of two or more domains andis typically constructed of materials of a few microns thickness ormore, which are permeable to oxygen and may or may not be permeable toglucose. In one example, the sensing membrane comprises an immobilizedglucose oxidase enzyme, which enables an electrochemical reaction tooccur to measure a concentration of glucose.

The term “sensor data,” as used herein is a broad term and is to begiven its ordinary and customary meaning to a person of ordinary skillin the art (and are not to be limited to a special or customizedmeaning), and furthermore refers without limitation to any dataassociated with a sensor, such as a continuous analyte sensor. Sensordata includes a raw data stream, or simply data stream, of analog ordigital signals directly related to a measured analyte from an analytesensor (or other signal received from another sensor), as well ascalibrated and/or filtered raw data. In one example, the sensor datacomprises digital data in “counts” converted by an A/D converter from ananalog signal (e.g., voltage or amps) and includes one or more datapoints representative of a glucose concentration. Thus, the terms“sensor data point” and “data point” refer generally to a digitalrepresentation of sensor data at a particular time. The terms broadlyencompass a plurality of time spaced data points from a sensor, such asfrom a substantially continuous glucose sensor, which comprisesindividual measurements taken at time intervals ranging from fractionsof a second up to, e.g., 1, 2, or 5 minutes or longer. In anotherexample, the sensor data includes an integrated digital valuerepresentative of one or more data points averaged over a time period.Sensor data may include calibrated data, smoothed data, filtered data,transformed data, and/or any other data associated with a sensor.

The term “sensor electronics,” as used herein, is a broad term, and isto be given its ordinary and customary meaning to a person of ordinaryskill in the art (and is not to be limited to a special or customizedmeaning) and refers without limitation to the components (for example,hardware and/or software) of a device configured to process data. Asdescribed in further detail hereinafter (see, e.g., FIG. 2) “sensorelectronics” may be arranged and configured to measure, convert, store,transmit, communicate, and/or retrieve sensor data associated with ananalyte sensor.

The terms “sensitivity” or “sensor sensitivity,” as used herein, arebroad terms, and are to be given their ordinary and customary meaning toa person of ordinary skill in the art (and is not to be limited to aspecial or customized meaning), and refer without limitation to anamount of signal produced by a certain concentration of a measuredanalyte, or a measured species (e.g., H₂O₂) associated with the measuredanalyte (e.g., glucose). For example, in one embodiment, a sensor has asensitivity from about 1 to about 300 picoamps of current for every 1mg/dL of glucose analyte.

The term “sample,” as used herein, is a broad term, and is to be givenits ordinary and customary meaning to a person of ordinary skill in theart (and it is not to be limited to a special or customized meaning),and refers without limitation to a sample of a host body, for example,body fluids, including, blood, serum, plasma, interstitial fluid,cerebral spinal fluid, lymph fluid, ocular fluid, saliva, oral fluid,urine, excretions, or exudates.

The term “distal to,” as used herein, is a broad term, and is to begiven its ordinary and customary meaning to a person of ordinary skillin the art (and is not to be limited to a special or customized meaning)and refers without limitation to the spatial relationship betweenvarious elements in comparison to a particular point of reference. Ingeneral, the term indicates an element is located relatively far fromthe reference point than another element.

The term “proximal to,” as used herein, is a broad term, and is to begiven its ordinary and customary meaning to a person of ordinary skillin the art (and is not to be limited to a special or customized meaning)and refers without limitation to the spatial relationship betweenvarious elements in comparison to a particular point of reference. Ingeneral, the term indicates an element is located relatively near to thereference point than another element.

The terms “electrical connection” and “electrical contact,” as usedherein, are broad terms, and are to be given their ordinary andcustomary meaning to a person of ordinary skill in the art (and are notto be limited to a special or customized meaning), and refer withoutlimitation to any connection between two electrical conductors known tothose in the art. In one embodiment, electrodes are in electricalconnection with (e.g., electrically connected to) the electroniccircuitry of a device. In another embodiment, two materials, such as butnot limited to two metals, can be in electrical contact with each other,such that an electrical current can pass from one of the two materialsto the other material and/or an electrical potential can be applied.

The term “elongated conductive body,” as used herein, is a broad term,and is to be given its ordinary and customary meaning to a person ofordinary skill in the art (and is not to be limited to a special orcustomized meaning), and refers without limitation to an elongated bodyformed at least in part of a conductive material and includes any numberof coatings that may be formed thereon. By way of example, an “elongatedconductive body” may mean a bare elongated conductive core (e.g., ametal wire), an elongated conductive core coated with one, two, three,four, five, or more layers of material, each of which may or may not beconductive, or an elongated non-conductive core with conductivecoatings, traces, and/or electrodes thereon and coated with one, two,three, four, five, or more layers of material, each of which may or maynot be conductive.

The term “ex vivo portion,” as used herein, is a broad term, and is tobe given its ordinary and customary meaning to a person of ordinaryskill in the art (and is not to be limited to a special or customizedmeaning), and refers without limitation to a portion of a device (forexample, a sensor) adapted to remain and/or exist outside of a livingbody of a host.

The term “in vivo portion,” as used herein, is a broad term, and is tobe given its ordinary and customary meaning to a person of ordinaryskill in the art (and is not to be limited to a special or customizedmeaning), and refers without limitation to a portion of a device (forexample, a sensor) adapted for insertion into and/or existence within aliving body of a host.

The term “potentiostat,” as used herein, is a broad term, and is to begiven its ordinary and customary meaning to a person of ordinary skillin the art (and is not to be limited to a special or customizedmeaning), and refers without limitation to an electronic instrument thatcontrols the electrical potential between the working and referenceelectrodes at one or more preset values.

The term “processor module,” as used herein, is a broad term, and is tobe given its ordinary and customary meaning to a person of ordinaryskill in the art (and are not to be limited to a special or customizedmeaning), and refers without limitation to a computer system, statemachine, processor, components thereof, and the like designed to performarithmetic or logic operations using logic circuitry that responds toand processes the basic instructions that drive a computer.

The term “sensor session,” as used herein, is a broad term and is to begiven its ordinary and customary meaning to a person of ordinary skillin the art (and is not to be limited to a special or customizedmeaning), and refers without limitation to a period of time a sensor isin use, such as but not limited to a period of time starting at the timethe sensor is implanted (e.g., by the host) to removal of the sensor(e.g., removal of the sensor from the host's body and/or removal of(e.g., disconnection from) system electronics).

The terms “substantial” and “substantially,” as used herein, are broadterms, and are to be given their ordinary and customary meaning to aperson of ordinary skill in the art (and are not to be limited to aspecial or customized meaning) and refer without limitation to asufficient amount that provides a desired function.

“Coaxial two conductor wire-based sensor”: A round wire sensorconsisting of a conductive center core, an insulating middle layer and aconductive outer layer with the conductive layers exposed at one end forelectrical contact.

“Pre-connected sensor”: A sensor that has a “sensorinterconnect/interposer/sensor carrier” attached to it. Therefore this“Pre-connected sensor” comprises two parts that are joined: the sensoritself, and the interconnect/interposer/sensor carrier. The term“pre-connected sensor” unit refers to the unit that is formed by thepermanent union of these two distinct parts.

Other definitions will be provided within the description below, and insome cases from the context of the term's usage.

As employed herein, the following abbreviations apply: Eq and Eqs(equivalents); mEq (milliequivalents); M (molar); mM (millimolar) μM(micromolar); N (Normal); mol (moles); mmol (millimoles); μmol(micromoles); nmol (nanomoles); g (grams); mg (milligrams); μg(micrograms); Kg (kilograms); L (liters); mL (milliliters); dL(deciliters); μL (microliters); cm (centimeters); mm (millimeters); μm(micrometers); nm (nanometers); h and hr (hours); min. (minutes); s andsec. (seconds); ° C. (degrees Centigrade) ° F. (degrees Fahrenheit), Pa(Pascals), kPa (kiloPascals), MPa (megaPascals), GPa (gigaPascals), Psi(pounds per square inch), kPsi (kilopounds per square inch).

Overview/General Description of System

In vivo analyte sensing technology may rely on in vivo sensors. In vivosensors may include an elongated conductive body having one or moreelectrodes such as a working electrode and a reference electrode.

For example, a platinum metal-clad, tantalum wire is sometimes used as acore bare sensing element with one or more reference or counterelectrodes for an analyte sensor. This sensing element is coated inmembranes to yield the final sensor.

Described herein, according to some embodiments, are pre-connectedsensors that include an analyte sensor attached to a sensor carrier(also referred to herein as a “sensor interposer”). The analyte sensormay include a working electrode and a reference electrode at a distalend of an elongated conductive body. The sensor carrier may include asubstrate, one or more electrical contacts coupled to one or moreelectrical contacts of the sensor, and circuitry such as one or moreadditional or external electrical contacts for coupling the one or moreelectrical contacts that are coupled to the sensor contact(s) toexternal equipment such as a membrane dip coating station, a testingstation, a calibration station, or sensor electronics of a wearabledevice. In some embodiments, the substrate can be referred to as anintermediate body.

Further described herein, according to some other embodiments, aresensors, including a working electrode and a reference electrode at adistal end of an elongated conductive body, that are directly attachedto a circuit board or substrate of a transmitter without the use of suchan above-mentioned sensor carrier. Utilization of a sensor that isdirectly attached and/or electrically connected to a circuit board orsubstrate of a transmitter without the use of such above-mentionedsensor carriers can allow for a more streamlined manufacturing processthat may comprise fewer steps and/or reduce manufacturing cost comparedto embodiments utilizing a sensor that is pre-connected to a sensorcarrier.

The following description and examples described the present embodimentswith reference to the drawings. In the drawings, reference numbers labelelements of the present embodiments. These reference numbers arereproduced below in connection with the discussion of the correspondingdrawing features.

Sensor System

FIG. 1 depicts an example system 100, in accordance with some exampleimplementations. The system 100 includes an analyte sensor system 101including sensor electronics 112 and an analyte sensor 138. The system100 may include other devices and/or sensors, such as medicamentdelivery pump 102 and glucose meter 104. The analyte sensor 138 may bephysically connected to sensor electronics 112 and may be integral with(e.g., non-releasably attached to) or releasably attachable to thesensor electronics. For example, in some embodiments, continuous analytesensor 138 may be connected to sensor electronics 112 via a sensorcarrier that mechanically and electrically interfaces the analyte sensor138 with the sensor electronics. In some other embodiments, continuousanalyte sensor 138 may be directly connected to sensor electronics 112without utilization of a sensor carrier that mechanically andelectrically interfaces the analyte sensor 138 with the sensorelectronics. The sensor electronics 112, medicament delivery pump 102,and/or glucose meter 104 may couple with one or more devices, such asdisplay devices 114, 116, 118, and/or 120.

In some example implementations, the system 100 may include acloud-based analyte processor 490 configured to analyze analyte data(and/or other patient-related data) provided via network 409 (e.g., viawired, wireless, or a combination thereof) from sensor system 101 andother devices, such as display devices 114, 116, 118, and/or 120 and thelike, associated with the host (also referred to as a patient) andgenerate reports providing high-level information, such as statistics,regarding the measured analyte over a certain time frame. A fulldiscussion of using a cloud-based analyte processing system may be foundin U.S. patent application Ser. No. 13/788,375, entitled “Cloud-BasedProcessing of Analyte Data” and filed on Mar. 7, 2013, published as U.S.Patent Application Publication 2013/0325352, herein incorporated byreference in its entirety. In some implementations, one or more steps ofthe factory calibration algorithm can be performed in the cloud.

In some example implementations, the sensor electronics 112 may includeelectronic circuitry associated with measuring and processing datagenerated by the analyte sensor 138. This generated analyte sensor datamay also include algorithms, which can be used to process and calibratethe analyte sensor data, although these algorithms may be provided inother ways as well. The sensor electronics 112 may include hardware,firmware, software, or a combination thereof, to provide measurement oflevels of the analyte via an analyte sensor, such as a glucose sensor.An example implementation of the sensor electronics 112 is describedfurther below with respect to FIG. 2. In one implementation, the factorycalibration algorithms described herein may be performed by the sensorelectronics.

The sensor electronics 112 may, as noted, couple (e.g., wirelessly andthe like) with one or more devices, such as display devices 114, 116,118, and/or 120. The display devices 114, 116, 118, and/or 120 may beconfigured for presenting information (and/or alarming), such as sensorinformation transmitted by the sensor electronics 112 for display at thedisplay devices 114, 116,118, and/or 120. In one implementation, thefactory calibration algorithms described herein may be performed atleast in part by the display devices.

In some example implementations, the relatively small, key fob-likedisplay device 114 may comprise a wrist watch, a belt, a necklace, apendent, a piece of jewelry, an adhesive patch, a pager, a key fob, aplastic card (e.g., credit card), an identification (ID) card, and/orthe like. This small display device 114 may include a relatively smalldisplay (e.g., smaller than the large display device 116) and may beconfigured to display certain types of displayable sensor information,such as a numerical value, and an arrow, or a color code.

In some example implementations, the relatively large, hand-held displaydevice 116 may comprise a hand-held receiver device, a palm-topcomputer, and/or the like. This large display device may include arelatively larger display (e.g., larger than the small display device114) and may be configured to display information, such as a graphicalrepresentation of the sensor data including current and historic sensordata output by sensor system 100.

In some example implementations, the analyte sensor 138 may comprise aglucose sensor configured to measure glucose in the blood orinterstitial fluid using one or more measurement techniques, such asenzymatic, chemical, physical, electrochemical, spectrophotometric,polarimetric, calorimetric, iontophoretic, radiometric, immunochemical,and the like. In implementations in which the analyte sensor 138includes a glucose sensor, the glucose sensor may comprise any devicecapable of measuring the concentration of glucose and may use a varietyof techniques to measure glucose including invasive, minimally invasive,and non-invasive sensing techniques (e.g., fluorescence monitoring), toprovide data, such as a data stream, indicative of the concentration ofglucose in a host. The data stream may be sensor data (raw and/orfiltered), which may be converted into a calibrated data stream used toprovide a value of glucose to a host, such as a user, a patient, or acaretaker (e.g., a parent, a relative, a guardian, a teacher, a doctor,a nurse, or any other individual that has an interest in the wellbeingof the host). Moreover, the analyte sensor 138 may be implanted as atleast one of the following types of analyte sensors: an implantableglucose sensor, a transcutaneous glucose sensor, implanted in a hostvessel or extracorporeally, a subcutaneous sensor, a refillablesubcutaneous sensor, an intravascular sensor.

Although the disclosure herein refers to some implementations thatinclude an analyte sensor 138 comprising a glucose sensor, the analytesensor 138 may comprise other types of analyte sensors as well.Moreover, although some implementations refer to the glucose sensor asan implantable glucose sensor, other types of devices capable ofdetecting a concentration of glucose and providing an output signalrepresentative of glucose concentration may be used as well.Furthermore, although the description herein refers to glucose as theanalyte being measured, processed, and the like, other analytes may beused as well including, for example, ketone bodies (e.g., acetone,acetoacetic acid and beta hydroxybutyric acid, lactate, etc.), glucagon,acetyl-CoA, triglycerides, fatty acids, intermediaries in the citricacid cycle, choline, insulin, cortisol, testosterone, and the like.

In some manufacturing systems, sensors 138 are manually sorted, placedand held in fixtures. These fixtures are manually moved from station tostation during manufacturing for various process steps includinginterfacing electrical measurement equipment for testing and calibrationoperations. However, manual handling of sensors can be inefficient, cancause delays due to non-ideal mechanical and electrical connections, andcan risk damage to the sensor and/or testing and calibration equipmentand can induce sensor variability that can lead to inaccurateverification data being collected in manufacturing. In addition, theprocess of packaging sensor 138 with the sensor electronics 112 into awearable device involves further manual manipulation of the sensor thatcan damage sensor 138.

Identification and other data associated with each sensor may be storedon the sensor carrier, if utilized, for logging and tracking of eachsensor during manufacturing, testing, calibration, and in vivooperations. Following testing and calibration operations, the sensorcarrier may be used to connect the sensor to sensor electronics of awearable device, such as an on-skin sensor assembly, in an arrangementthat is sealed and electrically robust. In embodiment not incorporatingsuch a sensor carrier, the sensor may be directly connected to thesensor electronics (e.g. to the printed circuit board of the sensorelectronics) of the wearable device.

FIG. 2 depicts an example of electronics 112 that may be used in sensorelectronics 112 or may be implemented in a manufacturing station such asa testing station, a calibration station, a smart carrier, or otherequipment used during manufacturing of device 101, in accordance withsome example implementations. The sensor electronics 112 may includeelectronics components that are configured to process sensorinformation, such as sensor data, and generate transformed sensor dataand displayable sensor information, e.g., via a processor module. Forexample, the processor module may transform sensor data into one or moreof the following: filtered sensor data (e.g., one or more filteredanalyte concentration values), raw sensor data, calibrated sensor data(e.g., one or more calibrated analyte concentration values), rate ofchange information, trend information, rate of acceleration/decelerationinformation, sensor diagnostic information, location information,alarm/alert information, calibration information such as may bedetermined by factory calibration algorithms as disclosed herein,smoothing and/or filtering algorithms of sensor data, and/or the like.

In some embodiments, a processor module 214 is configured to achieve asubstantial portion, if not all, of the data processing, including dataprocessing pertaining to factory calibration. Processor module 214 maybe integral to sensor electronics 112 and/or may be located remotely,such as in one or more of devices 114, 116, 118, and/or 120 and/or cloud490. For example, in some embodiments, processor module 214 may belocated at least partially within a cloud-based analyte processor 490 orelsewhere in network 409.

In some example implementations, the processor module 214 may beconfigured to calibrate the sensor data, and the data storage memory 220may store the calibrated sensor data points as transformed sensor data.Moreover, the processor module 214 may be configured, in some exampleimplementations, to wirelessly receive calibration information from adisplay device, such as devices 114, 116, 118, and/or 120, to enablecalibration of the sensor data from sensor 138. Furthermore, theprocessor module 214 may be configured to perform additional algorithmicprocessing on the sensor data (e.g., calibrated and/or filtered dataand/or other sensor information), and the data storage memory 220 may beconfigured to store the transformed sensor data and/or sensor diagnosticinformation associated with the algorithms. The processor module 214 mayfurther be configured to store and use calibration informationdetermined from a factory calibration, as described below.

In some example implementations, the sensor electronics 112 may comprisean application-specific integrated circuit (ASIC) 205 coupled to a userinterface 222. The ASIC 205 may further include a potentiostat 210, atelemetry module 232 for transmitting data from the sensor electronics112 to one or more devices, such as devices 114, 116, 118, and/or 120,and/or other components for signal processing and data storage (e.g.,processor module 214 and data storage memory 220). Although FIG. 2depicts ASIC 205, other types of circuitry may be used as well,including field programmable gate arrays (FPGA), one or moremicroprocessors configured to provide some (if not all of) theprocessing performed by the sensor electronics 12, analog circuitry,digital circuitry, or a combination thereof.

In the example depicted in FIG. 2, through a first input port 211 forsensor data the potentiostat 210 is coupled to an analyte sensor 138,such as a glucose sensor to generate sensor data from the analyte. Thepotentiostat 210 may be coupled to a working electrode 211 and referenceelectrode 212 that form a part of sensor 138. The potentiostat mayprovide a voltage to one of the electrodes 211, 212 of analyte sensor138 to bias the sensor for measurement of a value (e.g., a current)indicative of the analyte concentration in a host (also referred to asthe analog portion of the sensor). The potentiostat 210 may have one ormore connections to sensor 138 depending on the number of electrodesincorporated into the analyte sensor 138 (such as a counter electrode asa third electrode).

In some example implementations, the potentiostat 210 may include aresistor that translates a current value from sensor 138 into a voltagevalue, while in some example implementations, a current-to-frequencyconverter (not shown) may also be configured to integrate continuously ameasured current value from sensor 138 using, for example, acharge-counting device. In some example implementations, ananalog-to-digital converter (not shown) may digitize the analog signalfrom sensor 138 into so-called “counts” to allow processing by theprocessor module 214. The resulting counts may be directly related tothe current measured by the potentiostat 210, which may be directlyrelated to an analyte level, such as a glucose level, in the host.

The telemetry module 232 may be operably connected to processor module214 and may provide the hardware, firmware, and/or software that enablewireless communication between the sensor electronics 112 and one ormore other devices, such as display devices, processors, network accessdevices, and the like. A variety of wireless radio technologies that canbe implemented in the telemetry module 232 include Bluetooth, BluetoothLow-Energy, ANT, ANT+, ZigBee, IEEE 802.11, IEEE 802.16, cellular radioaccess technologies, radio frequency (RF), infrared (IR), paging networkcommunication, magnetic induction, satellite data communication, spreadspectrum communication, frequency hopping communication, near fieldcommunications, and/or the like. In some example implementations, thetelemetry module 232 comprises a Bluetooth chip, although Bluetoothtechnology may also be implemented in a combination of the telemetrymodule 232 and the processor module 214.

The processor module 214 may control the processing performed by thesensor electronics 112. For example, the processor module 214 may beconfigured to process data (e.g., counts), from the sensor, filter thedata, calibrate the data, perform fail-safe checking, and/or the like.

Potentiostat 210 may measure the analyte (e.g., glucose and/or the like)at discrete time intervals or continuously, for example, using acurrent-to-voltage or current-to-frequency converter.

The processor module 214 may further include a data generator (notshown) configured to generate data packages for transmission to devices,such as the display devices 114, 116, 118, and/or 120. Furthermore, theprocessor module 214 may generate data packets for transmission to theseoutside sources via telemetry module 232. In some exampleimplementations, the data packages may include an identifier code forthe sensor and/or sensor electronics 112, raw data, filtered data,calibrated data, rate of change information, trend information, errordetection or correction, and/or the like.

The processor module 214 may also include a program memory 216 and othermemory 218. The processor module 214 may be coupled to a communicationsinterface, such as a communication port 238, and a source of power, suchas a battery 234. Moreover, the battery 234 may be further coupled to abattery charger and/or regulator 236 to provide power to sensorelectronics 112 and/or charge the battery 234.

The program memory 216 may be implemented as a semi-static memory forstoring data, such as an identifier for a coupled sensor 138 (e.g., asensor identifier (ID)) and for storing code (also referred to asprogram code) to configure the ASIC 205 to perform one or more of theoperations/functions described herein. For example, the program code mayconfigure processor module 214 to process data streams or counts,filter, perform the calibration methods described below, performfail-safe checking, and the like.

The memory 218 may also be used to store information. For example, theprocessor module 214 including memory 218 may be used as the system'scache memory, where temporary storage is provided for recent sensor datareceived from the sensor. In some example implementations, the memorymay comprise memory storage components, such as read-only memory (ROM),random-access memory (RAM), dynamic-RAM, static-RAM, non-static RAM,electrically erasable programmable read only memory (EEPROM), rewritableROMs, flash memory, and the like.

The data storage memory 220 may be coupled to the processor module 214and may be configured to store a variety of sensor information. In someexample implementations, the data storage memory 220 stores one or moredays of analyte sensor data. The stored sensor information may includeone or more of the following: a time stamp, raw sensor data (one or moreraw analyte concentration values), calibrated data, filtered data,transformed sensor data, and/or any other displayable sensorinformation, calibration information (e.g., reference BG values and/orprior calibration information such as from factory calibration), sensordiagnostic information, and the like.

The user interface 222 may include a variety of interfaces, such as oneor more buttons 224, a liquid crystal display (LCD) 226, a vibrator 228,an audio transducer (e.g., speaker) 230, a backlight (not shown), and/orthe like. The components that comprise the user interface 222 mayprovide controls to interact with the user (e.g., the host).

The battery 234 may be operatively connected to the processor module 214(and possibly other components of the sensor electronics 12) and providethe necessary power for the sensor electronics 112. In otherimplementations, the receiver can be transcutaneously powered via aninductive coupling, for example.

A battery charger and/or regulator 236 may be configured to receiveenergy from an internal and/or external charger. In some exampleimplementations, the battery 234 (or batteries) is configured to becharged via an inductive and/or wireless charging pad, although anyother charging and/or power mechanism may be used as well.

One or more communication ports 238, also referred to as externalconnector(s), may be provided to allow communication with other devices,for example a PC communication (com) port can be provided to enablecommunication with systems that are separate from, or integral with, thesensor electronics 112. The communication port, for example, maycomprise a serial (e.g., universal serial bus or “USB”) communicationport, and allow for communicating with another computer system (e.g.,PC, personal digital assistant or “PDA,” server, or the like). In someexample implementations, factory information may be sent to thealgorithm from the sensor or from a cloud data source.

The one or more communication ports 238 may further include an inputport 237 in which calibration data may be received, and an output port239 which may be employed to transmit calibrated data, or data to becalibrated, to a receiver or mobile device. FIG. 2 illustrates theseaspects schematically. It will be understood that the ports may beseparated physically, but in alternative implementations a singlecommunication port may provide the functions of both the second inputport and the output port.

In some analyte sensor systems, an on-skin portion of the sensorelectronics may be simplified to minimize complexity and/or size ofon-skin electronics, for example, providing only raw, calibrated, and/orfiltered data to a display device configured to run calibration andother algorithms required for displaying the sensor data. However, thesensor electronics 112 (e.g., via processor module 214) may beimplemented to execute prospective algorithms used to generatetransformed sensor data and/or displayable sensor information,including, for example, algorithms that: evaluate a clinicalacceptability of reference and/or sensor data, evaluate calibration datafor best calibration based on inclusion criteria, evaluate a quality ofthe calibration, compare estimated analyte values with timecorresponding measured analyte values, analyze a variation of estimatedanalyte values, evaluate a stability of the sensor and/or sensor data,detect signal artifacts (noise), replace signal artifacts, determine arate of change and/or trend of the sensor data, perform dynamic andintelligent analyte value estimation, perform diagnostics on the sensorand/or sensor data, set modes of operation, evaluate the data foraberrancies, and/or the like.

FIGS. 3A, 3B, and 3C illustrate an exemplary implementation of analytesensor system 101 implemented as a wearable device such as an on-skinsensor assembly 500, 600. As shown in FIG. 3, on-skin sensor assemblycomprises a housing 128. An adhesive patch 126 can couple the housing128 to the skin of the host. The adhesive 126 can be a pressuresensitive adhesive (e.g. acrylic, rubber based, or other suitable type)bonded to a carrier substrate (e.g., spun lace polyester, polyurethanefilm, or other suitable type) for skin attachment. The housing 128 mayinclude a through-hole 180 that cooperates with a sensor inserter device(e.g., a sensor insertion needle, not shown) that is used for implantingsensor 138 under the skin of a subject.

The wearable sensor assembly 500, 600 can include sensor electronics 112(e.g., as at least a portion of electronics module 135) operable tomeasure and/or analyze glucose indicators sensed by glucose sensor 138.Sensor electronics 112 within sensor assembly 500, 600 can transmitinformation (e.g., measurements, analyte data, and glucose data) to aremotely located device (e.g., 114, 116, 118, 120 shown in FIG. 1). Asshown in FIG. 3C, in this implementation sensor 138 extends from itsdistal end up into through-hole 180 and is routed to an electronicsmodule 135 inside the enclosure 128. The working electrode 211 andreference electrode 212 are connected to circuitry in the electronicsmodule 135 which includes the potentiostat.

FIG. 3D illustrates one exemplary embodiment of an analyte sensor 138which includes an elongated body portion. The elongated body portion maybe long and thin, yet flexible and strong. For example, in someembodiments, the smallest dimension of the elongated conductive body isless than about 0.1 inches, 0.075 inches, 0.05 inches, 0.025 inches,0.01 inches, 0.004 inches, or 0.002 inches. While the elongatedconductive body is illustrated herein as having a circularcross-section, in other embodiments the cross-section of the elongatedconductive body can be ovoid, rectangular, triangular, or polyhedral,star-shaped, C-shaped, T-shaped, X-shaped, Y-shaped, irregular, or thelike.

In the implementation of FIG. 3D, the analyte sensor 138 comprises awire core 139. At a distal, in vivo portion of sensor 138, the wire core139 forms an electrode 211 a. At a proximal, ex vivo portion of sensor138, the wire core 139 forms a contact 211 b. The electrode 211 a andthe contact 211 b are in electrical communication over the length of thewire core 139 as it extends along the elongated body portion of sensor138. The wire core can be made from a single material such as platinumor tantalum, or may be formed as multiple layers, such as a conductingor non-conducting material with an outer coating of a differentconducting material.

A layer 104 surrounds a least a portion of the wire core 139. The layer104 may be formed of an insulating material, such as polyimide,polyurethane, parylene, or any other known insulating materials. Forexample, in one embodiment the layer 104 is disposed on the wire core139 and configured such that the electrode 211 a is exposed via window106.

In some embodiments, sensor 138 further comprises a layer 141surrounding the insulating layer 104 like a sleeve that comprises aconductive material. At a distal, in vivo portion of sensor 138, thesleeve layer 141 forms an electrode 212 a. At a proximal, ex vivoportion of sensor 138, the sleeve layer 141 forms a contact 212 b. Theelectrode 212 a and the contact 212 b are in electrical communicationover the length of the sleeve layer 141 as it extends along theelongated body portion of sensor 138. This sleeve layer 141 may beformed of a silver-containing material that is applied onto theinsulating layer 104. The silver-containing material may include any ofa variety of materials and be in various forms, such as, Ag/AgCl-polymerpastes, paints, polymer-based conducting mixture, and/or inks that arecommercially available, for example. This layer 141 can be processedusing a pasting/dipping/coating step, for example, using a die-metereddip coating process. In one exemplary embodiment, an Ag/AgCl polymerpaste is applied to an elongated body by dip-coating the body (e.g.,using a meniscus coating technique) and then drawing the body through adie to meter the coating to a precise thickness. In some embodiments,multiple coating steps are used to build up the coating to apredetermined thickness.

Sensor 138 shown in FIG. 3D also includes a membrane 108 covering atleast a portion of the distal in vivo portion of sensor 138. Thismembrane is typically formed of multiple layers, which may include oneor more of an interference domain, an enzyme domain, a diffusionresistance domain, and a bioprotective domain. This membrane isimportant to support the electrochemical processes that allow analytedetection and it is generally manufactured with great care bydip-coating, spraying, or other manufacturing steps. It is preferablefor the distal in vivo portion of sensor 138 to be subject to as littlehandling as possible or practical from the time the membrane 108 isformed to the time the distal in vivo portion of sensor 138 is implantedinto a subject. In some embodiments, electrode 211 a forms a workingelectrode of an electrochemical measuring system, and electrode 212 aforms a reference electrode for that system. In use, both electrodes maybe implanted into a host for analyte monitoring.

Although the above description is applicable specifically to a coaxialwire type structure, the embodiments herein are also applicable to otherphysical configurations of electrodes. For example, the two electrodes211 a and 212 a could be affixed to a distal in vivo portion of anelongated flexible strip of a planar substrate such as a thin, flat,polymer flex circuit. The two contacts 211 b and 212 b could be affixedto the proximal ex vivo portion of this flexible planar substrate.Electrodes 211 a, 212 a could be electrically connected to theirrespective contacts 211 b, 212 b via circuit traces on the planarsubstrate. In this case, the electrodes 211 a and 212 a and the contacts211 b and 212 b may be adjacent to one another on a flat surface ratherthan being coaxial as shown in FIG. 3D.

In some other embodiments, the two contacts 211 b and 212 b may becoupled directly to one or more contacts and/or traces of sensorelectronics 112 (see FIGS. 1 and 2) without utilization of such anabove-mentioned flexible strip of planar substrate, as will be describedin more detail in the following description.

Also shown in FIG. 3D is an illustration of the contact 211 b and thecontact 212 b electrically coupled to a simple current-to-voltageconverter based potentiostat 210. The potentiostat includes a battery320 that has an output coupled to an input of an operational amplifier322. The output of the operational amplifier 322 is coupled to a contact324 that is electrically coupled to the working electrode contact 211 bthrough a resistor 328. The amplifier 322 will bias the contact 324 tothe battery voltage Vb, and will drive the current i_(m) required tomaintain that bias. This current will flow from the working electrode211 a through the interstitial fluid surrounding sensor 138 and to thereference electrode 212 a. The reference electrode contact 212 b iselectrically coupled to another contact 334 which is connected to theother side of the battery 320. For this circuit, the current i_(m) isequal to (V_(b)−V_(m)), where V_(m) is the voltage measured at theoutput of the amplifier 322. The magnitude of this current for a givenbias on the working electrode 211 a is a measure of analyteconcentration in the vicinity of the window 106.

The contacts 324 and 334 are typically conductive pads/traces on acircuit board. There is always some level of parasitic leakage currenti_(p) over the surface of this board during the test. If possible, thisleakage current should not form part of the measurement of current dueto analyte. To reduce the effect this leakage current has on themeasured current, an optional additional pad/trace 336 may be providedbetween the biased contact 324 and the return contact 334 that isconnected directly to the battery output. This optional additionalpad/trace may be referred to as a “guard trace.” Because they are heldat the same potential, there will be essentially no leakage current fromthe biased contact 324 and the guard trace 336. Furthermore, leakagecurrent from the guard trace 336 to the return contact 334 does not passthrough the amplifier output resistor 328, and therefore is not includedin the measurement. Additional aspects and implementations of a guardtrace may be found in paragraphs [0128] and [0129] of U.S. PatentPublication 2017/0281092, which are incorporated herein by reference.

During manufacturing, various coating, testing, calibration, andassembly operations are performed on sensor 138. However, it can bedifficult to transport individual sensors and electrically interface thesensors with multiple testing and calibration equipment installations.These processes can also subject the sensors to damage from handling. Tohelp address these issues, sensor 138 may be provided as a part of apre-connected sensor that includes a sensor carrier as described ingreater detail below in connection with at least FIGS. 4A-4D and 5A-5C.

However, such pre-connected sensor embodiments may require additionalmanufacturing steps, which can undesirably increase manufacturing cost.Accordingly, in some other embodiments, at least a portion of sensor138, for example, contacts 211 b and 212 b may be coupled directly toone or more contacts and/or traces of sensor electronics 112 (e.g., atleast a portion of electronics module 135, see FIGS. 1 and 2) withoututilization of a sensor carrier, as will be described in greater detailbelow in connection with at least FIGS. 6A-6C, thereby reducing a numberof manufacturing steps and decreasing manufacturing complexity and/orcost.

Sensors Pre-Connected to a Sensor Carrier

FIG. 4A shows a schematic illustration of a pre-connected sensor 400. Asshown in FIG. 4A, pre-connected sensor 400 includes sensor carrier 402permanently attached to sensor 138. In the example of FIG. 4A, sensorcarrier 402 includes an intermediate body such as substrate 404, andalso includes one or more contacts such as first internal contact 406,and second internal contact 408. First internal contact 406 iselectrically coupled to a first contact on a proximal end of sensor 138and contact internal contact 408 is electrically coupled to a secondcontact on the proximal end of sensor 138. The distal end of sensor 138is a free end configured for insertion into the skin of the host.Contacts 406 and 408 may, for example, correspond to contacts 324 and334 of FIG. 3D in some implementations.

As shown in FIG. 4A, first internal contact 406 may be electricallycoupled to a first external contact 410 and second internal contact 408may be electrically coupled to a second external contact 412. Asdescribed in further detail hereinafter, external contacts 410 and 412may be configured to electrically interface with sensor electronics 112in a wearable device 500 (see FIGS. 5A-5C). Furthermore, externalcontacts 410 and 412 may be configured to electrically interface withprocessing circuitry of manufacturing equipment such as one or moretesting stations and/or one or more calibration stations. Althoughvarious examples are described herein in which two external contacts 410and 412 on the sensor carrier are coupled to two corresponding contactson sensor 138, this is merely illustrative. In other implementations,sensor carrier 402 and sensor 138 may each be provided with a singlecontact or may each be provided with more than two contacts, forexample, any number N of external contacts (e.g., more than two externalcontacts 410 and 412) of the sensor carrier and any number M of contacts(e.g., more than two contacts 406 and 408) of sensor 138 that can becoupled. In some implementations, sensor carrier 402 and sensor 138 mayhave the same number of contacts (i.e., N=M). In some implementations,sensor carrier 402 and sensor 138 may have a different number ofcontacts (i.e., N≠M). For example, in some implementations, sensorcarrier 402 may have additional contacts for coupling to or betweenvarious components of a manufacturing station.

As described in further detail hereinafter, substrate 404 may beconfigured to couple with sensor electronics 112 in wearable device 500.In some embodiments, substrate 404 may be sized and shaped tomechanically interface with housing 128 and electrically interface withsensor electronics 112 inside housing 128. Further, substrate 404 may besized and shaped to mechanically interface with manufacturing equipment,assembly equipment, testing stations and/or one or more calibrationstations. As described in further detail hereinafter, sensor carrier 402may be attached and/or electrically coupled to sensor 138. Sensor 138may be permanently coupled to a component of sensor carrier 402 (e.g.substrate 404) by using, for example, adhesive (e.g. UV cure, moisturecure, multi part activated, heat cure, hot melt, etc.), includingconductive adhesive (e.g. carbon filled, carbon nanotube filled, silverfilled, conductive additive, etc.), conductive ink, spring contacts,clips, wrapped flexible circuitry, a conductive polymer (e.g. conductiveelastomer, conductive plastic, carbon filled PLA, conductive graphenePLA), conductive foam, conductive fabric, a barrel connector, a moldedinterconnect device structure, sewing, wire wrapping, wire bonding, wirethreading, spot welding, swaging, crimping, stapling, clipping,soldering or brazing, plastic welding, or overmolding. In someembodiments, sensor 138 may be permanently coupled to substrate 404 byrivets, magnets, anisotropic conductive films, metallic foils, or othersuitable structures or materials for mechanically and electricallyattaching sensor carrier 402 to sensor 138 before or during assembly,manufacturing, testing and/or calibration operations. While theabove-described attachment techniques for sensor 138 are described inconnection with the use of sensor carrier 402, the present disclosurealso contemplated the use of any of the above-described techniques forattaching sensor 138 directly to an electronics assembly substrate, forexample electronics assembly substrate 630 as will be described in moredetail in connection with FIGS. 6A-6C below.

In some embodiments, sensor carrier 402 may be 3-D printed around sensor138 to form pre-connected sensor 400. Additionally, sensor carrier 402may include datum features 430 (sometimes referred to as datumstructures) such as a recess, an opening, a surface or a protrusion foraligning, positioning, and orienting sensor 138 relative to sensorcarrier 402. Sensor carrier 402 may also include, or may itself form,one or more anchoring features for securing and aligning the analytesensor during manufacturing (e.g., relative to a manufacturing station).Additionally, sensor carrier 402 may include an identifier 450configured to identify the sensor. In some embodiments, identifier 450is formed on substrate 404. Identifier 450 will be explained furtherbelow.

FIG. 4B illustrates another schematic of a pre-connected analyte sensor400. The pre-connected analyte sensor 400 shown in FIG. 4B may includesimilar components of pre-connected analyte sensor 400 shown in FIG. 4A.FIG. 4B is shown without optional cover 460 for clarity. FIG. 4Cillustrated an exploded view of pre-connected analyte sensor 400 shownin FIG. 4B.

In the example of FIG. 4B, sensor carrier 402 includes an intermediatebody such as a substrate 404, and also includes one or more traces suchas first trace 414 and second trace 416. First trace 414 may include afirst internal contact 406 and a first external contact 410. Secondtrace 416 may include a second internal contact 408 and a secondexternal contact 412. In some embodiments, first internal contact 406 iselectrically coupled to a first contact on a proximal end of sensor 138and second internal contact 408 is electrically coupled to a secondcontact on the proximal end of sensor 138. The distal end of sensor 138is a free end configured for insertion into the skin of the host. Theelectrical coupling may comprise clips, conductive adhesive, conductivepolymer, conductive ink, metallic foil, conductive foam, conductivefabric, wire wrapping, wire threading or any other suitable method. Insome embodiments, a non-conductive adhesive 426 (e.g. epoxy,cyanoacrylate, acrylic, rubber, urethane, hot melt, etc.) can be used toattach sensor 138 to substrate 404. Non-conductive adhesive 426 may beconfigured to affix, seal, insulate, or provide a strain relief tosensor 138. Sensor 138 may be attached to substrate 404 by othermethods, such as those described in FIG. 4A above.

As shown in FIG. 4C, a pressure sensitive adhesive 428 may be configuredto isolate an exposed end of traces 414 and 416. For instance, pressuresensitive adhesive 428 may laminate sensor 138 between substrate 404 andcover 460. In such instances, sensor 138, substrate 404, pressuresensitive adhesive 428, and cover 460 may form a laminatedconfiguration. In the laminated configuration, sensor 138 and itsconnection to one or more contacts (e.g. first internal contact 406 andsecond internal contact 408) are isolated from one or more exposedcontacts (e.g. first external contact 410 and second external contact412). Furthermore, the laminated configuration may create a moisturesealed region surrounding sensor 138. The moisture seal may be createdas embodied by a combination of a pressure sensitive adhesive 428 and anon-conductive adhesive 426. In other embodiments, the laminatedstructure can be created by one or a combination of the followingmaterials and methods: a non-conductive adhesive, a pressure sensitiveadhesive tape, an elastomer, heat bonding, hot plate welding, laserwelding, ultrasonic welding, RF welding, or any suitable type oflamination method. The cover 460 may consist of a polymer sheet,structure, or film that at least partially covers the substrate 404. Thecover 460 may optionally contain an identifier 450, which can identifysensor 138. In some embodiments, identifier 450 may incorporate variousidentification protocols or techniques such as, but not limited to, NFC,RFID, QR Code, Bar code, Wi-Fi, Trimmed resistor, Capacitive value,Impedance values, ROM, Memory, IC, Flash memory, etc.

Guide fixture 420, which is an optional component, is an exemplaryembodiment of an interface with a work station, such as a testingstation, a calibration station, an assembly station, a coating station,manufacturing stations, or as part of the wearable assembly. The guidefixture 420 includes datum features (or datum structures) 430, such as arecess, an opening, a surface or a protrusion for aligning, positioning,and orienting sensor 138 relative to sensor carrier 402. Datum features430 may be used in manufacturing and for assembly into a wearableelectronic component. In some embodiments, datum features 430 are raisedprotrusions configured to align with corresponding datum features 432 ofsubstrate 404. Corresponding datum features 432 of substrate 404 mayfeature cutouts, slots, holes, or recesses. The corresponding datumfeatures 432 in the sensor carrier may be placement features that caninterface with datum features 430 in a work station, such as a testingstation, a calibration station, an assembly station, a coating station,or other manufacturing stations. Guide fixture 420 may be configured toensure proper placement of the sensor carrier 402 to align the exposedexternal contacts 410 and 412 for connecting to a work station, such asa testing station, a calibration station, an assembly station, a coatingstation, or other manufacturing stations. In other embodiments, datumfeatures 430 may consist of female features to engage with malecorresponding datum features 432.

FIG. 4D illustrates a schematic view of an array 480 of pre-connectedanalyte sensors 400 having a plurality of pre-connected sensors 400 withoptional identifiers 450. In FIG. 4D, an array formed as aone-dimensional strip of pre-connected analyte sensors 400 is shown, buta two-dimensional array could also be implanted. In some embodiments,the array 480 of pre-connected analyte sensors may be disposed in acartridge. Each of the plurality of pre-connected sensors 400 can besingulated. In some embodiments, scoring 4020 may be provided tofacilitate singulation into individual pre-connected sensors 400. Insome embodiments, the array 480 can be used in facilitatingmanufacturing, testing and/or calibrating multiple sensors 138individually in sequential or random manners. In some embodiments, thearray 480 can be used in facilitating manufacturing, testing and/orcalibrating multiple sensors 138 concurrently.

FIGS. 5A and 5B show perspective views of an embodiment of a wearableassembly 500 including a pre-connected sensor 400. Wearable assembly 500may include sensor electronics and an adhesive patch (not shown).Pre-connected sensor 400 may include a sensor carrier such as sensorcarrier 402 described in FIGS. 4A-4D. The sensor carrier 402 may beplaced in or on housing 128. Housing 128 may be composed of two housingcomponents, top housing 520 and bottom housing 522. Top housing 520 andbottom housing 522 can be assembled together to form housing 128. Tophousing 520 and bottom housing 522 can be sealed to prevent moistureingress to an internal cavity of housing 128. The sealed housing mayinclude an encapsulating material (e.g. epoxy, silicone, urethane, orother suitable material). In other embodiments, housing 128 is formed asa single component encapsulant (e.g. epoxy) configured to contain sensorcarrier 402 and sensor electronics. FIGS. 5A illustrates an aperture 524within top housing 520 configured to allow for an insertion component(e.g. hypodermic needle, C-needle, V-needle, open sided needle, etc.) topass through the wearable assembly 500 for insertion and/or retraction.Aperture 524 may be aligned with a corresponding aperture in bottomhousing 522. In other embodiments, aperture 524 may extend through anoff-center location of housing 128. In other embodiments, aperture 524may extend through an edge of the housing 128, forming a C-shapedchannel. In some embodiments the aperture 524 includes a sealingmaterial such as a gel, adhesive, elastomer, or other suitable materiallocated within aperture 524.

FIG. 5B shows a perspective view of the bottom of wearable assembly 500.As illustrated, pre-connected sensor 400 may be disposed within thehousing 128. Pre-connected sensor 400 may be installed within anaperture 526 (sometimes referred to as an opening, a cavity, a void, aspace or a pocket) of bottom housing 522. As shown in the figure, sensor138 may extend out from aperture 526. Aperture 526 may be sized andshaped to retain pre-connected sensor 400. Furthermore, aperture 526 maybe sized and shaped to retain pre-connected sensor 400 in which sensor138 extends approximately parallel to the skin surface and forms a90-degree bend for insertion into the skin. It should be understood thatthe bottom surface of bottom housing 522 can contain an attachmentmember (e.g. an adhesive patch) for adhering the wearable assembly tothe skin surface of a user.

FIG. 5C shows an exploded view of the wearable assembly 500. Variouselectronic components such as the potentiostat 210 and other componentsillustrated in FIG. 2 may be mounted on or to an electronics assemblysubstrate 530, typically some form of printed circuit board. It iscontemplated that sensor carrier 402 has an electrical coupling withelectronics assembly substrate 530. Various methods may be used toestablish electrical connection (e.g. pins, solder, conductiveelastomer, conductive adhesive, etc.) between one or more contacts ofpre-connected sensor 400, such as external contacts 410 and 412 andelectronics assembly substrate 530. Sensor carrier 402 may be configuredto interface with electronics assembly substrate 530 through the bottomhousing 522. In other implementations, the sensor carrier 402 may beconfigured to interface with the electronics assembly substrate 530through top housing 520. In some other implementations, the sensorcarrier 402 is configured to interface with the electronics assemblysubstrate 530 through the side of wearable assembly 500. Also shown inthe figure, an optional sealing member 528 may be configured to insulateat least a portion of sensor carrier 402 from potential moistureingress. In some instances, the sealing member 528 may be liquiddispensed (e.g., adhesive, gel) or a solid material (e.g., elastomer,polymer). The sealing member 528 may be an assembled component that iswelded (e.g., laser or ultrasonic, hot plate), or otherwise permanentlyattached (e.g., anisotropic adhesive film, pressure sensitive adhesive,cyanoacrylate, epoxy, or other suitable adhesive) to create a sealedregion. The sealing member 528 may be used to physically couple and/orprovide a sealed region for the sensor carrier 402 to the wearableassembly 500.

It is one benefit of the analyte sensor connection techniques describedabove that the fabrication of the pre-connected sensor 400 may beseparated from the fabrication of the electronics (e.g., electronicsassembly substrate 530) enclosed within the housing. As described abovewith reference to the pre-connected sensor structure and the subsequentcoating, testing and calibrating processes, the housing with theinternally contained electronics can be manufactured in a separatefacility from the one that attaches the pre-connected sensor 400 to thesensor electrical interface. This is made possible by providing ananalyte sensor electronics interface that is accessible from outside thehousing. The housing need not be opened to attach the sensor.

In some advantageous methods, the electrodes for the pre-connectedsensor are fabricated and mounted on the substrate in a first locationand are shipped to a second location for coating, testing andcalibrating. The housing with internal electronics is manufactured in athird location. The housing with the electronics is shipped from thethird location to the second location, where the completed analytesensor is attached to the external electrical interface. The threelocations can all be remote from each other. This minimizes handling ofthe sensitive membrane coated sensor, but still allows separatemanufacturing of the other components of the complete device.

Sensors Directly Connected to an Electronics Assembly Substrate of aWearable Assembly

FIG. 6A shows a perspective view of an embodiment of a wearable assembly600 having a sensor 138 directly connected to an electronics assemblysubstrate 630 via a first conductive contact 324 and a second conductivecontact 334 (see FIGS. 6B and 6C) on which sensor electronics 112 can bedisposed, according to some embodiments. While not shown in FIG. 6A,wearable assembly 600 may include an adhesive patch 126. Housing 128 maycomprise two housing components, a top housing 620 and a bottom housing622. Top housing 620 and bottom housing 622 can be assembled together toform housing 128. Top housing 620 and bottom housing 622 can be sealedto prevent moisture ingress to at least one internal cavity of housing128. The sealed housing may include an encapsulating material 628 (e.g.epoxy, silicone, urethane, or other suitable material). In otherembodiments, housing 128 is formed as a single component encapsulant(e.g. epoxy) configured to contain at least a proximal portion of sensor138 and sensor electronics 112. FIGS. 6A illustrates an aperture 624within top housing 620 configured to allow for an insertion component(e.g. hypodermic needle, C-needle, V-needle, open sided needle, etc.) topass through wearable assembly 600 for insertion and/or retraction.Aperture 624 may be aligned with a corresponding aperture (not shown) inbottom housing 622. In other embodiments, aperture 624 may extendthrough an off-center location of housing 128. In other embodiments,aperture 624 may extend through an edge of the housing 128, forming aC-shaped channel. In some embodiments aperture 624 includes a sealingmaterial such as a gel, adhesive, elastomer, or other suitable materiallocated within aperture 624.

FIG. 6B shows a plan view of the bottom of wearable assembly 600,according to some embodiments. As illustrated, sensor 138 may bedirectly connected to electronics assembly substrate 630, within thehousing 128, via conductive contacts 324, 334, which may extend fromelectronics assembly substrate 630 through a portion of lower housing622 and into a cavity of housing 622 within which electrodes of sensor138 are disposed. Sensor 138 may be installed within an aperture 626 ofbottom housing 622. As shown in FIGS. 6A and 6C, sensor 138 may extendout from aperture 626. Aperture 626 may be sized and shaped to retain atleast the proximal portion of sensor 138. Sensor 138 may extendapproximately parallel to the skin surface and form a 90-degree bend forinsertion into the skin. It should be understood that the bottom surfaceof bottom housing 622 can contain an attachment member (e.g. an adhesivepatch 126, not shown) for adhering the wearable assembly to the skinsurface of a user.

FIG. 6C shows a side cutaway view of wearable assembly 600 alongcut-line 6C-6C of FIG. 6B, according to some embodiments. Variouselectronic components such as the potentiostat 210 and other componentsillustrated in FIG. 2 may be mounted on or to electronics assemblysubstrate 630, typically some form of printed circuit board. It iscontemplated that sensor 138 has a direct electrical coupling withelectronics assembly substrate 630. Various methods may be used toestablish electrical connection (e.g. pins, solder, conductiveelastomer, conductive adhesive, etc.) between one or more contacts orelectrodes of sensor 138, such as contacts 211 b and 212 b, and one ormore conductive contacts, such as contacts 324, 334 electrically and/orphysically coupled to electronics assembly substrate 630. Sensor 138 maybe configured to interface with electronics assembly substrate 630through the bottom housing 622. In other implementations, sensor 138 maybe configured to interface with electronics assembly substrate 630through top housing 620. In some other implementations, sensor 138 isconfigured to interface with electronics assembly substrate 630 throughthe side of wearable assembly 600. Also shown in the figure, an optionalsealing member 628 may be configured to insulate at least a portion ofsensor 138 and from potential moisture ingress. In some instances, asealing member 628 may be liquid dispensed (e.g., adhesive, gel, epoxy)or a solid material (e.g., elastomer, polymer). The sealing member 628may be an assembled component that is welded (e.g., laser or ultrasonic,hot plate), or otherwise permanently attached (e.g., anisotropicadhesive film, pressure sensitive adhesive, cyanoacrylate, epoxy, orother suitable adhesive) to create a sealed region or cavity. In someembodiments, the sealing member 628 may be used to physically secure orcouple at least a portion of sensor 138 to wearable assembly 600 and/orto provide a sealed region for at least a proximal portion of sensor138.

It is one benefit of the analyte sensor connection techniques describedabove that the fabrication and/or manufacture of wearable assembly 600can require fewer steps compared to the embodiments utilizing thepre-connected sensor 400 of FIGS. 4A-5C, thereby decreasingmanufacturing complexity and cost. Caps for Simultaneously Sealing fromMoisture Ingress and Securing a Sensor

In some embodiments, it is desirable that sensor 138 and/or sensorelectronics 112 (see FIG. 1 and, e.g., electronics module 135 of FIG.3C) be sealed from the outside environment to prevent moisture fromseeping into or condensing onto such components, as such moisture cancause shorting, oxidation, or otherwise cause damage. One such solutionmay be to fill an encapsulating sealant into at least a portion of acavity within which at least a portion of sensor 138 is disposed.However, care must be taken that such encapsulating sealant does notinappropriately flow to certain other portions of the cavity, or suchencapsulating sealant may undesirably occlude other features of wearableassembly 600, for example, through-hole 180 for a needle or other sensorinsertion member to pass during deployment of wearable assembly 600. Inaddition, sensor 138 may need to be held in place while suchencapsulating sealant is deployed and/or cured to avoid permanentmispositioning of sensor 138. For example, applying pressure to apressure-sensitive adhesive in contact with sensor 138 may tend to movesensor 138, causing misalignment. As another example, when using acurable epoxy to set sensor 138 in place, extra fixturing may seemnecessary to datum sensor 138 in place during epoxy curing to avoidmisalignment.

Some example solutions for simultaneously holding sensor 138 in placewhile also ensuring encapsulating sealant does not inappropriately flowto undesired portions of a cavity of housing 128 are described in moredetail in connection with several of the following figures.

FIGS. 7A and 7B illustrate perspective views of a cap 700 for sealingaperture 624 within housing 128, according to some embodiments. FIG. 7Cillustrates a perspective view of cap 700 disposed over aperture 626within housing 128, according to some embodiments.

As illustrated in FIG. 7C, aperture 626 within lower housing 622 forms,provides or defines a cavity 750 within which sensor electronics 112 isdisposed (e.g., on electronics assembly substrate 630). A first portion752 of cavity 750 may hold at least a portion of sensor 138. A secondportion 754 of cavity 750 may include at least through-hole 180. Whenproperly placed, sensor 138 may be directly electrically contacted tosensor electronics 112 on electronics assembly substrate 630, forexample via conductive contacts 324, 334, and may have portions disposedwithin first portion 752 and second portion 754 of cavity 750. Asfurther shown in FIG. 7C, at least a portion of sensor 138 may beadhered to housing 622 utilizing any suitable glue 724, for example a UVcuring glue, epoxy or the like, as will be described in more detail inconnection with various figures below.

As shown in FIG. 7A, cap 700 is configured to cover, fit into, or fit onaperture 626 of lower housing 622, thereby providing a controlled fillvolume within first portion 752 of cavity 750 while at the same timepressing sensor 138 to an inner surface of cavity 750 and/or of lowerhousing 622, thereby also acting as a datuming feature for sensor 138.In some embodiments, cap 700 may comprise a molded part, a die-cut sheetof material, or any other suitable form. In some embodiments, cap 700may have an adhesive, for example a pressure-sensitive adhesive, on oneside (not shown) for securing cap 700 into or over aperture 626.

Cap 700 comprises a first portion 710 configured to be disposed overfirst portion 752 of the cavity 750 and a second portion 720 configuredto be disposed over second portion 754 of the cavity 750. In someembodiments, first and second portions 710, 720 of cap 700 may becoplanar and may be formed of a single piece. First portion 710 of cap700 may further comprise a first hole 702 configured as an inlet portfor receiving an encapsulating sealant (e.g., a curable epoxy) intofirst portion 752 of cavity 750 for sealing at least a portion of sensor138 from moisture. First portion 710 of cap 700 may further comprise asecond hole 704 configured as an outlet port for excess encapsulatingsealant injected into first portion 752 of cavity 750 through first hole702. In some embodiments, first hole 702 and second hole 704 may bedisposed near opposite ends of first portion 710 of cap 700 to therebyprovide for complete or near-complete filling of first portion 752 ofcavity 750 with the encapsulating sealant.

Cap 700 may further comprise an encapsulant dam 730 disposed on a sideof cap 700 configured to face aperture 626. In some embodiments,encapsulant dam 730 may have a height sufficient for encapsulant dam 730to contact a surface of lower housing 622 within cavity 750 when cap 700is properly placed within or on aperture 626. In some other embodiments,encapsulant dam 730 may have a slightly lower height than just describedto allow encapsulant dam 730 to nearly contact the surface of lowerhousing 622 within cavity 750 when cap 700 is properly placed within oron aperture 626.

Cap 700 may further comprise an optional shelf 732 disposed adjacent todam 730 and configured to receive a compliant component 740 (e.g., asoft, foam or rubber material, see FIG. 7B). In some embodiments, shelf732 may have a height such that a surface of compliant component 740,configured to face aperture 626, extends slightly farther from cap 700than a similarly facing surface of dam 730. When cap 700 is properlyplaced within or on aperture 626, compliant component 740 is configuredto press against at least a portion of sensor 138 and against thesurface of lower housing 622 within cavity 750. Accordingly, compliantcomponent 740 datums sensor 138 to the surface of lower housing 622within cavity 750 in a compliant manner and seals first portion 752 ofcavity 750 from second portion 754 of cavity 750. In some embodiments,dam 730 can further assist in sealing first portion 752 of cavity 750from second portion 754 of cavity 750. Accordingly, when encapsulatingsealant is injected into first portion 752 of cavity 750 to seal atleast some portions of sensor 138 from moisture ingress, dam 730 and/orcompliant component 740 prevent the encapsulating sealant from flowinginto second portion 754 of cavity 750, thereby preventing undesirableocclusion of through-hole 180, while also providing assembly tolerancesbetween cap 700, aperture 626, and/or lower housing 622.

Second portion 720 of cap 700 may further comprise a slot 722 configuredto allow at least a distal portion of sensor 138 to pass through cap700. Utilizing slot 722 in cap 700 instead of a circular hole may allowa smaller through-hole 180 in wearable assembly 600.

In some embodiments, an outside-facing surface of cap 700 may beconfigured to fit nominally flush with an outside-facing surface oflower housing 622 when properly placed. In the alternative, theoutside-facing surface of cap 700 may be configured to fit slightlyrecessed compared to the outside-facing surface of lower housing 622when properly placed. In such nominally-flush or slightly-recessedembodiments, an outer perimeter of cap 700 may substantially correspondto an inner perimeter of aperture 626.

FIG. 7D illustrates a perspective view of cap 700 disposed flush orslightly recessed within aperture 626 of housing 128, according to someembodiments. Cap 700 may be held in place during encapsulating sealantdeposition using toe features, snap features, friction-fit features,pressure-sensitive adhesive, or any other suitable securing method. Insome embodiments, cap 700 may comprise a material transparent orsufficiently translucent to ultraviolet radiation to allow for curing ofa UV-curing epoxy encapsulating sealant disposed in first portion 752 ofcavity 750.

In yet another alternative, cap 700 may be configured to cover aperture626 while being disposed flush on the outside-facing surface of lowerhousing 622. In such other alternatives, an outer perimeter of cap 700may be larger than the inner perimeter of aperture 626 and may have anysize and shape up to and including an outer perimeter of lower housing622 (not shown). In such embodiments, cap 700 may be adhered to theoutside-facing surface of lower housing 622 at portions of lower housing622 outside the inner perimeter of aperture 626, which may aid inultimately adhering wearable assembly 600 to a flat surface of skin.

While cap 700 is described above as utilized in connection with wearableassembly 600, which does not include pre-connected sensor 400 or sensorcarrier 402, the present disclosure is not so-limited and cap 700 mayalso be utilized with wearable assembly 500 comprising pre-connectedsensor 400.

In some embodiments, rather than utilizing a separate adhesive foradhering cap 700 to lower housing 622, the adhesive portion normallyutilized to adhere patch 126 to lower housing 622 of wearable assembly600 may be repurposed to additionally adhere or otherwise secure cap 700to lower housing 622 once properly placed in, on or over lower housing622. For example, as shown in FIG. 8A, patch 126 may comprise two parts:a first adhesive portion 802 configured to secure cap 700 to lowerhousing 622 and to simultaneously adhere lower housing 622 of wearableassembly 600 to patch 126, and a second adhesive portion 804 configuredto adhere the first adhesive portion 802, and so wearable assembly 600,to the skin of the user.

FIG. 8B illustrates an outward-facing surface of cap 700 secured tofirst adhesive portion 802. First adhesive portion 802 may compriseapertures or holes configured to coincide with first and second holes702, 704 of cap 700 and through-hole 180 of wearable assembly 600 whencap 700 is properly placed on, flush with, or recessed within aperture626 of lower housing 622.

In an alternative embodiment, as shown in FIG. 8C, cap 700 may beomitted and first adhesive portion 802 may comprise first and secondholes 702, 704 and an aperture or hole configured to coincide withthrough-hole 180 of wearable assembly 600 when first adhesive portion802 is properly placed on lower housing 622. In such an alternativeembodiment, first adhesive portion 802 may further comprise compliantcomponent 740 having substantially the same functionality as previouslydescribed in connection with FIGS. 7A-7D. Accordingly, properly placingand applying first adhesive portion 802 on lower housing 622 causescompliant component 740 to press against at least a portion of sensor138 and against the surface of lower housing 622 within cavity 750.Accordingly, compliant component 740 datums sensor 138 to the surface oflower housing 622 within cavity 750 in a compliant manner and also sealsfirst portion 752 of cavity 750 from second portion 754 of cavity 750.Accordingly, when encapsulating sealant is injected into first portion752 of cavity 750 to seal sensor electronics 112 and at least a portionof sensor 138 from moisture ingress, compliant component 740 preventsthe encapsulating sealant from flowing into second portion 754 of cavity750, thereby preventing undesirable occlusion of through-hole 180.

Regardless of whether embodiments shown in FIG. 8B or 8C are used,second adhesive portion 804 may be initially disposed on a liner 806,which may be removed and second adhesive portion 804 placed, separately,on an outside-facing surface of first adhesive portion 802 of patch 126for subsequent securing of wearable assembly 600 onto the skin of theuser. As shown in FIG. 8D, second adhesive portion 804 may furthercomprise an aperture or hole 880 b configured to coincide withthrough-hole 180 of wearable assembly 600 when second adhesive portion804 is properly placed on the outside-facing surface of first adhesiveportion 802 of patch 126.

FIG. 9 illustrates a cutaway side view of an alternative cap 900 to cap700, according to some embodiments. Like numerals between cap 900 andcap 700 correspond to similar features. Cap 900 comprises a firstportion 910 configured to be disposed over first portion 752 of cavity750 in lower housing 622 and a second portion 920. In some embodiments,second portion 920 is configured to be disposed over second portion 754of cavity 750, which may comprise through-hole 180 in lower housing 622.In other embodiments, second portion 920 is configured to be disposedadjacent to second portion 754 of cavity 750. First portion 910comprises a first hole 902 configured as an inlet port for receiving anencapsulating sealant (e.g., epoxy) into first portion 752 of cavity 750for sealing at least a portion of sensor 138 from moisture ingress.First portion 910 of cap 900 may further comprise a second hole 904configured as an outlet port for excess encapsulating sealant injectedinto first portion 752 of cavity 750 through first hole 902. In someembodiments, first hole 902 and second hold 904 may be disposed nearopposite ends of the first portion 910 of cap 900 to thereby provide forcomplete or near-complete filling of first portion 752 of cavity 750with the encapsulating sealant.

Cap 900 may further comprise an encapsulant dam 930. However, unlikewith cap 700, first and second portions 910, 920 of cap 900 may not becoplanar and encapsulant dam 930 may instead comprise at least a portionof cap 900 that extends between the planes of and connects first andsecond portions 910, 920. Accordingly, at least a portion of secondportion 920 disposed adjacent to dam 930 may also function as a shelf932 configured to receive a compliant component 940 (e.g., a soft, foamor rubber material). When cap 900 is properly placed within or onaperture 626, compliant component 940 is configured to press against atleast a portion of sensor 138 and against the surface of lower housing622 within cavity 750. Accordingly, compliant component 940 datumssensor 138 to the surface of lower housing 622 within cavity 750 in acompliant manner and also, with or without the help of dam 930, sealsfirst portion 752 of cavity 750 from second portion 754 of cavity 750.Accordingly, when encapsulating sealant is injected into first portion752 of cavity 750 to seal at least a portion of sensor 138 from moistureingress, dam 930 and/or compliant component 940 prevent theencapsulating sealant from flowing into second portion 754 of cavity750, thereby preventing undesirable occlusion of through-hole 180, whilealso providing assembly tolerances between cap 900, aperture 626, and/orlower housing 622.

Although not shown in FIG. 9, second portion 920 of cap 900 may furthercomprise a slot, similar to slot 722 of cap 700, configured to allow atleast a distal portion of sensor 138 to pass through cap 900 when cap900 is properly placed. Alternatively, in some embodiments where secondportion 920 of cap 900 does not extend laterally to through-hole 180,such a slot may be omitted.

While cap 900 is described above as utilized in connection with wearableassembly 600, which does not include pre-connected sensor 400, thepresent disclosure is not so-limited and cap 900 may also be utilizedwith wearable assembly 500 comprising pre-connected sensor 400 andsensor carrier 402.

In some embodiments it may be advantageous to mount or bond sensor 138to a cap before assembly of wearable assembly 600 and provide one ormore pairs of mating contacts on the cap and on wearable assembly 600for connection of the sensor to the electronics in wearable assembly 600(e.g., sensor electronics 112) when the cap is properly placed on lowerhousing 622 of wearable assembly 600.

FIG. 10 illustrates a perspective view of a cap 1000 having sensor 138pre-mounted thereto, according to some embodiments. FIG. 10 illustratescap 1000 having an outward-facing side adhered to patch 126, similar toprevious description in connection with FIG. 8B. Cap 1000 comprises athrough-hole 1080 configured to line up with through-hole 180 ofwearable assembly 600 when cap 1000 is properly placed on lower housing622. Sensor 138 may be adhered or otherwise secured to a top face of cap1000 such that a distal portion of sensor 138 extends throughthrough-hole 1080 and away from cap 1000. Cap 1000 further comprises afirst trace 1022 and a second trace 1032. First trace 1022 is configuredto electrically connect contact 211 b of sensor 138 to a first contact1024 on cap 1000. Second trace 1032 is configured to electricallyconnect contact 212 b of sensor 138 to a second contact 1034 on cap1000. As shown in the figure, lower housing 622 is illustrated as havinga plurality of contacts, e.g., contacts 324 and 334, disposed on itsoutward-facing surface. First and second contacts 1022 and 1024 areconfigured to make direct electrical and physical contact withrespective contacts 324 and 334 when cap 1000 is properly placed onlower housing 622, thereby electrically coupling sensor 138 to sensorelectronics 112. Cap 1000 may be bonded, adhered or otherwise attachedto lower housing 622 utilizing any suitable means.

Utilizing Sensor Bend Geometry to Locate and Hold the Sensor on a PCB

Due to the small size of sensor 138, and constraints on acceptablehandling locations along its length, establishing proper alignment ofsensor 138 on wearable assembly 600 can be challenging, particularlywhen there is no carrier or handle attached to sensor 138 prior tointegration with electronics assembly substrate 630, and especiallywhere sensor 138 has a substantially cylindrical or otherwise at leastpartially rounded shape. In addition, the natural curvature of sensor138, which can be difficult to straighten, may cause sensor 138 to movearound undesirably when handled. Utilization of a single pre-bend in thedistal region of sensor 138 has limited usefulness in preventing suchundesirable movement at the time of placing sensor 138 within wearableassembly 600 due to the single pre-bend's proximity to the needlethrough-hole 180 and to membrane 108. Accordingly, several solutionsthat utilize sensor bend geometry to assist with lateral and rotationallocation of sensor 138 relative to electronics assembly substrate 630(e.g., a transmitter PCB) are described below in connection with atleast FIGS. 11A-20.

The utilization of such bends, kinks, loops and/or curves in sensor 138,established by one or more pre-forming step(s), provides retainingfeatures in sensor 138 at points that are spaced apart sufficiently toprovide support, constraint, bias force, and/or location of sensor 138relative to features on wearable assembly 600 and/or on electronicsassembly substrate 630. These geometries may also be desirably utilizedto increase the leakage current path between electrodes on sensor 138 byleveraging a longer insulation region and/or by bending sensor 138 insuch a manner that the resultant distance between the electrode pads isincreased compared to a straight, unbent, or singly-bent sensor 138.Moreover, intentionally bending sensor 138 at multiple points along itslength can create a more easily-handled shape that can mimic a flatsurface on which sensor 138 can rest. Moreover, as will be described inmore detail below, the elastic properties of sensor 138 can also beleveraged to generate a biasing or retention force against one or morefeatures of electronics assembly substrate 630 and/or of housing 622,thereby causing sensor 138 to remain in place before applying subsequentmechanical features and/or adhesives.

FIGS. 11A-11C separately illustrate three main types of bends in sensor138, according to some embodiments. While embodiments are described forsensor 138 in relation to electronics assembly substrate 630, thepresent disclosure also contemplates similar embodiments for sensor 138in relation to lower housing 622. For example, at least a portion oflower housing 622 may physically separate electronics assembly substrate630 from the portion of lower housing 622 in which at least portions ofsensor 138 extends (see, e.g., at least FIGS. 6A-7D and 9), Where sensor138 is described as contacting, extending in a particular direction withrespect to, or applying a force or torque to a surface of electronicsassembly substrate 630, the present disclosure additionally and/oralternatively contemplates such contact, direction of extension, and/orapplying of force or torque to surfaces of lower housing 622.

FIG. 11A illustrates side and top views of a first type of sensor bend1102 a, in which sensor 138 is bent so a portion of sensor 138 proximalto electronics assembly substrate 630 extends in a direction towardswearable assembly 600, for example, such that the proximal portion ofsensor 138 extends through electronics assembly substrate 630. FIG. 11Billustrates side and top views of a second type of sensor bend 1102 b,in which sensor 138 is bent so the portion of sensor 138 proximal toelectronics assembly substrate 630 extends in a direction away fromwearable assembly 600, for example, such that the proximal portion ofsensor 138 extends away from electronics assembly substrate 630. FIG.11C illustrates side and top views of a third type of sensor bend 1102c, in which sensor 138 is bent so the portion of sensor 138 proximal toelectronics assembly substrate 630 extends in a direction neither towardnor away from wearable assembly 600, but substantially parallel to theplane of electronics assembly substrate 630 to which it is mountedand/or electrically connected.

While several examples of each type of sensor bend are described below,the present disclosure contemplates any and all combinations of suchexamples, with or without additional bends and/or features of sensor138. Moreover, although embodiments are generally described as relatingto the wearable assembly 600, which does not include pre-connectedsensor 400, the present disclosure is not so-limited and suchembodiments may also be utilized with wearable assembly 500 comprisingpre-connected sensor 400 and sensor carrier 402. Several exampleembodiments of the first type of sensor bend, as illustrated in FIG.11A, will now be described in connection with FIGS. 12 and 13 below.

FIG. 12 shows a side, cutaway view of an example arrangement including asensor bend 1202 that causes the proximal portion of sensor 138 toextend through electronics assembly substrate 630, according to someembodiments. FIG. 12 illustrates lower housing 622 of wearable assembly600, electronics assembly substrate 630 disposed on lower housing 622,and sensor 138, comprising a plurality of bends 1202, 1204, disposed onand mechanically and electrically coupled to electronics assemblysubstrate 630.

Electronics assembly substrate 630 is illustrated as comprising a PCBmaterial such as FR4, although the present disclosure is not so-limitedand any suitable PCB material is also contemplated. Electronics assemblysubstrate 630 further comprises a plurality of electrical contacts, forexample contacts 324, 334 as previously described in connection with atleast FIG. 3D. In FIG. 12, contact 324 is illustrated as anelectrically-conductive, plated through-hole, although the presentdisclosure is not so-limited and any other suitable contact is alsocontemplated.

Sensor 138 is illustrated as having a first bend 1202 at a proximalportion of sensor 138 and a second bend 1204 at a medial or distalportion of sensor 138, such that a portion of the elongated body ofsensor 138 distal of first bend 1202 extends substantially parallel to aplane of electronics assembly substrate 630 and a portion of theelongated body proximal to first bend 1202 extends substantiallyperpendicular to the plane of electronics assembly substrate 630 andthrough electronics assembly substrate 630. In some embodiments, firstbend 1202 may be an approximately 90° bend. However, the presentdisclosure is not so-limited and first bend 1202 may have any suitablebend angle. In some embodiments, first bend 1202 occurs along theworking electrode contact 211 b such that at least a portion of contact211 b passes through the through-hole contact 324, thereby establishingmechanical positioning of sensor 138 before conductive connections(e.g., epoxy, solder, or the like) are applied to electrically connectcontacts 211 b and 324 and to electrically connect contacts 212 b and334, for example.

Additionally, in some embodiments, lower housing 622 may furthercomprise a molded geometry comprising one or more features configured tosupport electronics assembly substrate 630 and/or sensor 138 at or nearsecond bend 1204. For example, electronics assembly substrate 630 can beconfigured to rest on a portion of lower housing 622. Lower housing 622can further comprise one or more ridges, recesses, or surfaces 1212,1214 configured to abut one or more respective edges (e.g., lateraledges) of electronics assembly substrate 630. Among other advantages,the one or more ridges, recesses, or surfaces 1212, 1214 provide formore accurate placement of electronics assembly substrate 630 withrespect to lower housing 622.

In addition, and/or alternative, lower housing 622 can comprise a recess1216 immediately below plated through-hole contact 324 that allows forthe proximal portion of sensor 138 to extend through electronicsassembly substrate 630 and, in some cases, at least partially into therecess 1216. Among other advantages, recess 1216 provides additionalassembly tolerances for placement of sensor 138 on electronics assemblysubstrate 630.

In addition, and/or alternative, lower housing 622 can comprise a notch1218 configured to align a medial and/or distal portion of sensor 138at, near or adjacent to second bend 1204. Among other advantages, notch1218 provides additional alignment and restricts undesirable movement ofsensor 138 prior to and after securing sensor 138 to electronicsassembly substrate 630 and/or to lower housing 622.

In some embodiments, a bend of the first type (e.g., substantiallyparallel to the plane of electronics assembly substrate 630 tosubstantially perpendicular and through the plane of electronicsassembly substrate 630) may be utilized to purposefully exploit theelastic properties of sensor 138 to generate a biasing or retentionforce against one or more features of electronics assembly substrate 630and/or of wearable assembly 600.

For example, FIG. 13 shows a side, cutaway view of an examplearrangement including a first sensor bend 1302 that causes the proximalportion of sensor 138 to extend through electronics assembly substrate630 while simultaneously presenting a biasing force against electronicsassembly substrate 630, according to some embodiments. Electronicsassembly substrate 630 is shown as comprising contact 324, which may bean electrically-conductive, plated through-hole, as previously describedin connection with FIG. 12, or which may alternatively be a planarplated contact at least partially surrounding the illustratedthrough-hole in electronics assembly substrate 630, or a conductive pinor post configured to extend through lower housing 622 to reachconnecting portions of sensor 138, as previously described in connectionwith at least FIGS. 6A-9. Contact 334 may similarly comprise such aconductive pin or post.

Sensor 138 is illustrated as having first bend 1302 at a proximalportion of sensor 138 and second bend 1204, as previously described inconnection with FIG. 12, at a medial or distal portion of sensor 138.First bend 1302 may cause a direction of extension of the proximalportion of sensor 138 to transition, by a desired angle (e.g., between1-179°), from substantially in-plane with electronics assembly substrate630 to substantially angled through-plane with respect to electronicsassembly substrate 630 such that at least some of the proximal portionof sensor 138 contacts and exerts a biasing force against a portion ofelectronics assembly substrate 630 (e.g., a sidewall of thethrough-hole). This will cause the sidewall of the through-hole to exertan equal but opposite biasing force on the proximal portion of sensor138, thereby securing sensor 138 in a desired orientation and positionbefore conductive connections (e.g., epoxy, solder, or the like) areapplied between or to the proximal portion of sensor 138 and the contact324 and between or to an appropriate portion of sensor 138 and thecontact 334.

Several example embodiments of the second type of sensor bend, asillustrated in FIG. 11B, will now be described in connection with FIGS.14A-16 below. FIG. 14A shows a top view of an example arrangementincluding a sensor bend 1402 that causes the proximal portion of sensor138 to extend away from electronics assembly substrate 630 (e.g., out ofplane), according to some embodiments. FIG. 14B illustrates a side,cutaway view of the arrangement of FIG. 14A. Discussion below referencesboth figures. The figures illustrate lower housing 622 of wearableassembly 600, electronics assembly substrate 630 disposed on, oralternatively within, lower housing 622, and sensor 138, comprising aplurality of bends 1402, 1204, disposed on and electrically coupled toelectronics assembly substrate 630.

Electronics assembly substrate 630 may comprise a PCB material such asFR4, although the present disclosure is not so-limited and any suitablePCB material is also contemplated. Electronics assembly substrate 630further comprises a plurality of electrical contacts, for example,contacts 324, 334 as previously described in connection with at leastFIG. 3D.

Sensor 138 is illustrated as having a first bend 1402 at a proximalportion of sensor 138 and second bend 1204, as previously described inconnection with FIG. 12, at a medial or distal portion of sensor 138. Aportion of the elongated body of sensor 138 distal of first bend 1302extends substantially parallel to a plane of electronics assemblysubstrate 630 and a portion of the elongated body proximal to first bend1302 extends substantially perpendicular to the plane of electronicsassembly substrate 630 and away from electronics assembly substrate 630.In some embodiments, the first bend 1402 occurs along the workingelectrode contact 211 b.

Lower housing 622 may further comprise a molded geometry comprising oneor more features configured to support electronics assembly substrate630 and/or sensor 138 at or near each of the first bend 1402 and secondbend 1204. For example, electronics assembly substrate 630 can beconfigured to rest on a portion of lower housing 622. Lower housing 622can further comprise one or more ridges, recesses, or surfaces 1412,1414 configured to abut one or more respective edges (e.g., lateraledges) of electronics assembly substrate 630. Among other advantages,the one or more ridges, recesses, or surfaces 1412, 1414 provide formore accurate placement of electronics assembly substrate 630 withrespect to lower housing 622.

In addition, and/or alternative, lower housing 622 can comprise a recess1416 in a sidewall of lower housing 622 immediately adjacent contact 324that allows for the proximal portion of sensor 138 to extendsubstantially perpendicularly away from and with respect to electronicsassembly substrate 630 and at least partially within the recess 1416.Among other advantages, recess 1416 establishes mechanical positioningof sensor 138 before conductive connections (e.g., epoxy, solder, or thelike) are applied to electrically connect contacts 211 b and 324 and toelectrically connect contacts 212 b and 334, for example.

In addition, and/or alternative, lower housing 622 can comprise a notch1418 configured to align a medial and/or distal portion of sensor 138at, near or adjacent to second bend 1204. Among other advantages, notch1418 provides additional alignment and restricts undesirable movement ofsensor 138 prior to and after securing sensor 138 to electronicsassembly substrate 630 and/or to lower housing 622.

In some embodiments, a bend of the second type (e.g., substantiallyparallel to a plane of electronics assembly substrate 630 tosubstantially perpendicular to and away from electronics assemblysubstrate 630) may be utilized to purposefully exploit the elasticproperties of sensor 138 to generate a biasing or retention forceagainst one or more features of electronics assembly substrate 630and/or of lower housing 622. Examples are described below in connectionwith FIGS. 15 and 16.

FIG. 15 shows a side, cutaway view of an example arrangement including asensor bend 1502 that causes the proximal portion of sensor 138 toextend away from electronics assembly substrate 630 while simultaneouslypresenting a biasing force against lower housing 622, according to someembodiments. For ease of illustration and discussion, contacts on sensor138 and on electronics assembly substrate 630 are not shown.

Sensor 138 is illustrated as having a first bend 1502 at a proximalportion of sensor 138 and second bend 1204, as previously described inconnection with FIG. 12, at a medial or distal portion of sensor 138.The first bend 1502 may cause a direction of extension of the proximalportion of sensor 138 to transition, by a desired angle (e.g., between90-180°), from substantially in-plane with electronics assemblysubstrate 630 to substantially angled out-of-plane with respect toelectronics assembly substrate 630 such that at least some of theproximal portion of sensor 138 contacts and exerts a biasing forceagainst a sidewall of lower housing 622, for example, against a sidewallwithin recess 1416 as previously described in connection with FIG. 14.This will cause the sidewall of lower housing 622 to exert an equal butopposite biasing force on the proximal portion of sensor 138, therebysecuring sensor 138 in a desired orientation and position beforeconductive connections (e.g., epoxy, solder, or the like) are appliedbetween or to the proximal portion of sensor 138 and contact 324 andbetween or to an appropriate portion of sensor 138 and contact 334.

FIG. 16A shows a first side view of an example arrangement includingmultiple sensor bends 1602, 1204, 1606, 1608, 1610, at least some ofwhich cause biasing forces against portions of lower housing 622,according to some embodiments. FIG. 16B shows a second side view of theexample arrangement of FIG. 16A taken along the section line B-B′ inFIG. 16A.

Sensor 138 is illustrated as having a first bend 1602 at a proximalportion of sensor 138, one or more additional bends 1606, 1608, 1610proximal to the first bend 1602, and the bend 1204, as previouslydescribed in connection with FIG. 12, at a medial or distal portion ofsensor 138 that is distal to bends 1602, 1606, 1608, 1610. The firstbend 1602 may cause a direction of extension of the proximal portion ofsensor 138 to transition, by a desired angle (e.g., approximately 90°),from substantially parallel to the plane of electronics assemblysubstrate 630 to substantially perpendicular to the plane of and awayfrom electronics assembly substrate 630. In some embodiments, at leastsome portions of sensor 138 proximal to first bend 1602 may be disposedwithin a recess in a sidewall of lower housing 622, for example, recess1406 as previously described in connection with FIG. 14.

As shown in FIG. 16B, the one or more additional bends 1606, 1608, 1610cause portions of sensor 138 proximal to first bend 1602 to extend atangles with respect to opposing sidewalls 1622, 1624 of recess 1406.Accordingly, sensor 138 contacts and exerts biasing forces against thesidewalls 1622, 1624 of recess 1406 at least at the locations of bends1606, 1608, 1610. Exertion of such biasing forces by sensor 138 willcause the sidewalls 1622, 1624 to exert equal but opposite biasingforces on the proximal portion of sensor 138. The result of thesebiasing forces can secure sensor 138 in a desired orientation andposition before conductive connections (e.g., epoxy, solder, or thelike) are applied between or to an appropriate portion of sensor 138 andcontact 324 and between or to another appropriate portion of sensor 138and contact 334 (not shown in FIGS. 16A-16B). As shown, the biasingforces F_(bias), exerted normal to the points of contact between sensor138 and the sidewalls 1622, 1624, will cause a frictional forceF_(friction) in a direction parallel to sidewalls 1622 at the points ofcontact between sensor 138 and the sidewalls 1622, 1624 to resistmovement of sensor 138 with respect to lower housing 622 and electronicsassembly substrate 630. Among other advantages, the one or moreadditional bends 1606, 1608, 1610 provide additional alignment andrestrict undesirable movement or rotation of, and centerline constraintfor, sensor 138 prior to and after securing sensor 138 to electronicsassembly substrate 630 and/or to lower housing 622.

Several example embodiments of the third type of sensor bend, asillustrated in FIG. 11C, will now be described in connection with FIGS.17-20 below. FIG. 17 shows a top view of an example arrangementincluding a sensor bend 1702 that causes the proximal portion of sensor138 to maintain extension substantially in-plane with respect toelectronics assembly substrate 630, according to some embodiments. FIG.17 illustrates electronics assembly substrate 630 and sensor 138,comprising at least bend 1702, disposed on and electrically coupled toelectronics assembly substrate 630.

Electronics assembly substrate 630 may comprise a PCB material such asFR4, although the present disclosure is not so-limited and any suitablePCB material is also contemplated. Electronics assembly substrate 630further comprises a plurality of electrical contacts, for example,contacts 324, 334, 336 as previously described in connection with atleast FIG. 3D. As previously described, contact 336 may comprise a guardtrace.

Sensor 138 is illustrated as having at least a first bend 1702 at aproximal portion of sensor 138. The first bend 1702 may cause adirection of extension of the proximal portion of sensor 138 totransition from substantially in-plane with electronics assemblysubstrate 630, by any desired in-plane angle (shown as approximately 90°in FIG. 17), such that at least a portion of sensor 138 proximal to thefirst bend 1702 remains substantially in-plane with electronics assemblysubstrate 630. In some embodiments, the first bend 1702 occurs along theinsulation layer 104, which in some embodiments may comprisepolyurethane or any other suitable electrical insulator. Although notshown in FIG. 17, sensor 138 may comprise any number of additionalbends, for example second bend 1204, as previously described inconnection with FIG. 12, at a medial or distal portion of sensor 138.

Contact 212 b of sensor 138 may be in mechanical and electrical contactwith contact 334. Insulation layer 104 may be in mechanical andelectrical contact with contact 336. Contact 211 b of sensor 138 may bein mechanical and electrical contact with contact 324. Among otheradvantages, the first bend 1702, by redirecting at least a first portionof sensor 138 between the contact 211 b and the contact 212 b to extendin a different, in-plane direction compared to a second portion ofsensor 138 between the contact 211 b and the contact 212 b, allows thecontacts 211 b, 212 b to be separated by a greater linear distance alongsensor 138 and so separated by a greater linear length of insulationlayer 104. This may be at least partly a function of the limiteddimension of electronics assembly substrate 630 in any single direction.By causing portions of sensor 138 to extend in at least two differentin-plane directions with respect to electronics assembly substrate 630,the contacts 211 b, 212 b may be separated by a greater linear distancealong sensor 138. In addition, the first bend 1702, by causing portionsof sensor 138 to extend in at least two different in-plane directionswith respect to electronics assembly substrate 630, provides at leastthree in-plane points of contact (e.g., contacts 324, 334, 336) thatcreate a more easily handled shape and that can mimic a flat surface forwhich sensor 138 can rest.

In some embodiments, a bend of the third type (e.g., changing adirection of extension of at least a portion of sensor 138 whileremaining substantially in-plane with electronics assembly substrate630) may be utilized to purposefully exploit the elastic properties ofsensor 138 to generate a biasing or retention force against one or morefeatures of electronics assembly substrate 630 and/or of wearableassembly 600. Examples are described below in connection with FIGS.18-20.

FIG. 18 shows a top view of an example arrangement including multiplesensor bends 1802, 1804, 1806, at least some of which cause a biasingforce against portions 1822, 1824 of lower housing 622 or electronicsassembly substrate 630, according to some embodiments.

Sensor 138 is illustrated as having a first bend 1802 at a proximalportion of sensor 138 and one or more additional bends 1804, 1806proximal to the first bend 1802. Although not shown in FIG. 18, sensor138 may further comprise the bend 1204, as previously described inconnection with FIG. 12, at a medial or distal portion of sensor 138that is distal to bends 1802, 1804, 1806.

The one or more additional bends 1804, 1806 cause portions of sensor 138proximal to first bend 1802 to extend at angles with respect to opposingsidewalls 1822, 1824 of lower housing 622 and/or of electronics assemblysubstrate 630 such that sensor 138 contacts and exerts biasing forcesF_(bias) against the sidewalls 1822, 1824 at least at the locations ofbends 1804, 1806, which will cause the sidewalls 1822, 1824 to exertequal but opposite biasing forces on the proximal portion of sensor 138,thereby securing sensor 138 in a desired orientation and position beforeconductive connections (e.g., epoxy, solder, or the like) are appliedbetween or to contacts 211 b and 324 and between or to contacts 212 band 334.

Similar to that previously described in connection with FIG. 16, thebiasing forces F_(bias), exerted normal to the points of contact betweensensor 138 and the sidewalls 1822, 1824, will cause a frictional forceF_(friction) in a direction parallel to sidewalls 1822, 1824 at thepoints of contact between sensor 138 and the sidewalls 1822, 1824 toresist movement of sensor 138 with respect to lower housing 622 andelectronics assembly substrate 630. Among other advantages, the one ormore additional bends 1804, 1806 provide additional alignment andrestrict undesirable movement or rotation of, and centerline constraintfor, sensor 138 prior to and after securing sensor 138 to electronicsassembly substrate 630 and/or to lower housing 622.

FIG. 19 shows a top view of an example arrangement including at leastone sensor bend 1902, which substantially immobilizes or anchors sensor138 to a pin or post 1912 of or fabricated on a portion of the housing128, for example lower housing 622 or electronics assembly substrate630, according to some embodiments.

Sensor 138 is illustrated as having a first bend 1902 at a proximalportion of sensor 138. In some embodiments, the first bend 1902 is an atleast partially circumferential bend configured to wrap a proximalportion of the sensor at least partway around a pin or post 1912, whichmay comprise a part of contact 324 which can be a part of electronicsassembly substrate 630. The first bend 1902 may change a direction ofextension of at least a portion of sensor 138 while remainingsubstantially in-plane with electronics assembly substrate 630.

Among other advantages, the first bend 1902, extending at leastpartially around a circumference or perimeter of pin or post 1912,secures sensor 138 in a desired orientation and position beforeconductive connections (e.g., epoxy, solder, or the like) are appliedbetween or to contacts 211 b and 324 and between or to contacts 212 band 334. Accordingly, the arrangement of FIG. 19 also provides alignmentand restricts undesirable movement or rotation of, and centerlineconstraint for, sensor 138 prior to and after securing sensor 138 toelectronics assembly substrate 630 and/or to lower housing 622.

Although not shown in FIG. 19, sensor 138 may further comprise the bend1204, as previously described in connection with FIG. 12, at a medial ordistal portion of sensor 138 that is distal to bends 1902, 1904, 1906.

FIG. 20 shows a top view of an example arrangement including at leastone sensor bend 2002, which causes at least one biasing force Fl, F2, F3against one or more portions 2012, 2014, 2016 of lower housing 622 or ofelectronics assembly substrate 630, according to some embodiments.

Sensor 138 is illustrated as having a first bend 2002 at a proximalportion of sensor 138. First bend 2002 causes portions of sensor 138proximal to first bend 2002 to change a direction of extension of atleast a portion of sensor 138 while remaining substantially parallel tothe plane of electronics assembly substrate 630. For example, first bend2002 is illustrated as occurring along the portion of sensor 138 wherethe insulated layer 104 is present and exposed. However, the presentdisclosure is not so limited and first bend 2002 can occur along anysuitable portion of sensor 138. First bend 2002 is illustrated as havingan angle of less than 90°. However, the present disclosure is notso-limited and any suitable bend angle may be utilized, depending on theparticular context of the situation and the layout of the particularfeatures of wearable assembly 600.

A first portion of sensor 138 may be configured to contact a firstsidewall or other feature 2012 of lower housing 622 or of electronicsassembly substrate 630. In FIG. 20, this first portion of sensor 138 isillustrated as a portion of the reference electrode or contact 212 b.However, the present disclosure is not so-limited and any other portionof sensor 138 is also contemplated.

Sensor 138 may be configured to contact a second sidewall or otherfeature 2014 of lower housing 622 or of electronics assembly substrate630 at the location of first bend 2002.

A second portion of sensor 138 may be configured to contact a thirdsidewall or other feature 2016 of lower housing 622 or of electronicsassembly substrate 630. In FIG. 20, this third portion of sensor 138 isillustrated as a portion of the working electrode or contact 211 bproximal of first bend 2002. However, the present disclosure is notso-limited and any other portion of sensor 138 is also contemplated.

In FIG. 20, a contacting surface of first sidewall 2012 and biasingforce F1 are illustrated as facing substantially perpendicular to adirection of extension of the first portion of sensor 138 (e.g., thereference electrode) and substantially perpendicular to respectivecontacting surfaces of each of the second and third sidewalls 2014,2016. However, the present disclosure is not so limited and thecontacting surface of first sidewall 2012 can have any suitableorientation(s) with respect to any of the first portion of sensor 138and/or the respective contacting surfaces of each of the second andthird sidewalls 2014, 2016.

In FIG. 20, the respective contacting surfaces of the second and thirdsidewalls 2014, 2016 and biasing forces F2 and F3 are illustrated asfacing in opposite directions. However, the present disclosure is notso-limited and the respective contacting surfaces of the second andthird sidewalls 2014, 2016 and biasing forces F2 and F3 can have anysuitable orientation(s) with respect to one another and/or with respectto any other features of wearable assembly 600.

Sensor 138 may be initially bent at first bend 2002 to an angle lessthan the ultimate angle illustrated in FIG. 20 or desired in actualimplementation and then placed in the illustrated or desiredorientation, thereby increasing the angle of first bend 2002 slightlybeyond the initial bend angle. As illustrated in FIG. 20, due to theelastic and/or resilient properties of sensor 138, sensor 138 willexhibit a tendency to attempt to reduce the angle of first bend 2002from the illustrated angle toward the initial bend angle. This tendencywill cause sensor 138 to develop at least one biasing or retentionforce(s) F1, F2, F3 in directions substantially normal to and againstthe points of contact with the one or more respective sidewalls 2012,2014, 2016 of electronics assembly substrate 630 and/or of lower housing622.

For example, as illustrated, the tendency of sensor 138 to decrease thebend angle of first bend 2002 will cause a torque at first bend 2002that pushes the second portion of sensor 138 against the contactingsurface of the third sidewall 2016 with a force F3, producing an equalbut opposite biasing force on the second portion of sensor 138. Thisopposite biasing force will push sensor 138 against the contactingsurface of the second sidewall 2014 at first bend 2002 with a force F2,producing an equal but opposite biasing force on sensor 138 at firstbend 2002.

The torque at first bend 2002 caused by the tendency of sensor 138 todecrease the bend angle of first bend 2002 will also push the firstportion of sensor 138 against the contacting surface of first sidewall2012 with the force F1, producing an equal but opposite biasing force onthe first portion of sensor 138.

The biasing or retaining forces F1, F2, F3 will also cause orthogonalfrictional forces (not shown) in respective directions parallel to thesidewalls 2012, 2014, 2016 at the points of contact that will furtherresist movement of sensor 138 with respect to lower housing 622 andelectronics assembly substrate 630. Alone or in combination, thesebiasing, retaining and/or frictional forces act to secure sensor 138 ina desired orientation and position before conductive connections (e.g.,epoxy, solder, or the like) are applied between or to contacts 212 b and324 and between or to contacts 211 b and 334.

Among other advantages, first bend 2002 provides additional alignmentand restricts undesirable movement or rotation of, and centerlineconstraint for, sensor 138 prior to and after securing sensor 138 toelectronics assembly substrate 630 and/or to lower housing 622.Utilizing Substrate Dams to Form Wells for Direct-to-Board SensorConnection

With some sensor wire direct-to-board designs, conductive epoxies orother adhesive epoxies used at different locations to bond sensor 138 tothe PCB (e.g., electronics assembly substrate 630) can bleed or runtogether, undesirably causing electrical shorts, or otherwiseundesirably bleed or run along the sensor into adjacent areas. Severalsolutions are described below in connection with at least FIGS. 21A-27.

FIG. 21A shows a top view of a portion of a wearable assembly 600comprising a plurality of dams 2112, 2114, 2116 that form a plurality ofwells 2102, 2104 for containing and preventing undesirable bleeding ormigration of epoxy 2122, 2124, according to some embodiments. FIGS. 21B,21C and 21D each show side cutaway views of the portion of wearableassembly 600 illustrated in FIG. 21A taken along cut-lines A-A′, B-B′and C-C′, respectively. The portion of wearable assembly 600 shown inFIGS. 21A-21D may be fabricated according to any suitable process, forexample low pressure overmolding of electronics assembly substrate 630and/or of lower housing 622. Further discussion follows with referenceto each of FIGS. 21A-21D.

FIG. 21B illustrates electronics assembly substrate 630 comprisingcontacts 324, 334 as previously described in connection with at leastFIG. 3D. An overmold structure 2150 may be formed on, over, around or asan integral part of electronics assembly substrate 630, for exampleutilizing a low-pressure overmolding process. Such a low-pressureovermolding process can allow full shut off around electronics assemblysubstrate 630, thereby sealing portions of electronics assemblysubstrate 630 from moisture ingress and leaving less of electronicsassembly substrate 630 exposed for subsequent potting processes.

Overmold structure 2150 comprises a plurality of dams 2112, 2114, 2116spaced adjacent to contacts 324, 334. Contacts 324 and 334 may each be acontact pad or plate disposed on electronics assembly substrate 630. Insome embodiments, contacts 324 and 334 may be formed by gold plating. Asshown, contacts 324 and 334 are rectangular shaped. In otherembodiments, contacts 324 and 334 may be circular shaped, oval shaped,diamond shaped, rounded rectangular shaped, rounded diamond shaped,polygonal-shaped, or rounded polygonal shaped. As illustrated, first dam2112 is disposed adjacent to a first side of contact 334. Second dam2114 is disposed adjacent to a second side of contact 334 opposite thefirst side, between contacts, 324, 334, and adjacent to a first side ofcontact 324. Third dam 2116 is disposed adjacent to a second side ofcontact 324 opposite the first side. Accordingly, first and second dams2112, 2114 define a first well 2102 within which contact 334 isdisposed, while second and third dams 2114, 2116 define a second well2104 within which contact 324 is disposed. As shown in FIG. 21D,sidewalls 2132 and 2134, disposed on opposite sides of contact 324, formthe remaining walls of second well 2104. While not explicitly shown andlabeled in FIGS. 21A-21D, a similar pair of sidewalls, are disposed onopposite sides of contact 334 thereby forming the remaining walls offirst well 2102.

Once wells 2102, 2104 are formed, conductive epoxy 2122, 2124 can bedeposited over contacts 324, 334 within wells 2102, 2104 in preparationfor sensor 138 placement.

As shown in FIGS. 21C and 21D, at least one of dams 2112, 2114, 2116 canhave a sloped cross-section, as viewed perpendicular to cut lines B-B′or C-C′. For example, dams 2112, 2114, 2116 can have a triangularly-,parabolically-, semi-circularly-, hyperbolically- or otherwise-recessedcross-section having a lowest point substantially equidistant fromcorresponding sidewalls of the respective wells along the cross-section(e.g., sidewalls 2132, 2134 for second well 2104), or at any otherdesired location along the cross-section(s). Respective portions ofsensor 138 are configured to rest substantially at this lowest point ofthe recess or cross-section of each of dams 2112, 2114, 2116 due totheir sloped or notched character. Accordingly, dams 2112, 2114, 2116not only define wells 2102, 2104 but also guide the respective portionsof sensor 138 to desired locations before they are secured in place.

In some embodiments, one or more of the dams (e.g., third dam 2116 asshown in FIGS. 21A-21B) may have a substantially flat cross-section,rather than the sloped cross-section described above. For example, wherefirst and second dams 2112, 2114 have the above-described slopedcross-section and adequately constrain at least lateral positioning ofsensor 138, third dam 2116 need not have the sloped cross-section andthe flat cross-section may merely serve as a platform on which theproximal end of sensor 138 rests.

As shown in at least FIGS. 21B and 21D, epoxy 2122, 2124 can bedeposited in each of wells 2102, 2104 at least to a minimum height. Insome embodiments, such a minimum height is sufficiently large thatrespective portions of sensor 138 physically and electrically contact atleast the top surface of epoxy 2122, 2124 when sensor 138 is disposedtransversely across dams 2112, 2114, 2116, as shown in FIG. 21A. Forexample, contact 212 b (of a reference electrode) can contact conductiveepoxy 2122 disposed on contact 334 in first well 2102, while contact 211b (of a working electrode) can contact conductive epoxy 2124 disposed oncontact 324 in second well 2104. A portion of sensor 138 distal to theportion of contact 212 b contacting conductive epoxy 2122 can rest onfirst dam 2112, insulation layer 104 of sensor 138 can rest on seconddam 2114, and a portion of sensor 138 proximal to the portion of contact211 b contacting conductive epoxy 2124 can rest on third dam 2116.

As shown in FIG. 21B, conductive epoxy 2122 may fill in a void in firstwell 2102 between contact 334 of electronics assembly substrate 630 andcontact 212 b of sensor 138 (e.g. reference electrode). As such,conductive epoxy 2122 may physically separate contact 334 and contact212 b. One advantage of this separation may be the reduction of signalnoise or signal shift of sensor 138 that can occur when contact 334 andcontact 212 b are in physical contact. It is contemplated that, in someinstances, the material of contact 212 b of the reference electrode maygalvanically react with the material of contact 334 of electronicsassembly substrate 630. For example, contact 212 b may comprise silverand silver chloride and contact 334 may comprise gold, nickel, andcopper. It is contemplated that the galvanic interaction between goldand silver/silver chloride or copper and silver/silver chloride mayresult in corrosion of contact 334. Thus, filling in the space betweencontact 334 and contact 212 b with conductive epoxy 2122 may reducecorrosion of contact 334. In some embodiments, contact 334 may have achannel (not shown) extending through a middle of the contact to allowfor conductive epoxy to be deposited. In other embodiments, contact 334may have an intermediate layer (not shown) disposed over contact 334that separates contact 334 and contact 212 b. In such embodiments, theintermediate layer may comprise plastic, epoxy, or a composite materialsuch as FR4. It is also contemplated that in embodiments where contact334 is in physical contact with contact 212 b (for example, FIG. 15), acarbon conductive ink may be disposed over an underlying copper layer ofcontact 334. The carbon conductive ink would replace the more commongold layer in which it is contemplated that the carbon in the carbonconductive ink has lower galvanic potential which would increaseresistance to corrosion. In some embodiments, a corrosion inhibiterlayer may be formed on contact 334 to increase resistance to corrosion.It is also contemplated that any of the above features and techniquesmay be applied to contact 324 as well.

In some embodiments where sensor 138 is attached directly to electronicsassembly substrate 630 without utilizing a separate sensor carrier,sensor 138 may be handed off to wearable assembly 600 from a placementgripper during manufacture. Such a “hand-off” method should maintain theposition of sensor 138 as placed by such a placement gripper while anepoxy, for example an ultraviolet curing epoxy, can be used to seal oradhere sensor 138 to electronics assembly substrate 630. However, thisepoxy must be prevented from running along sensor 138 into adjacentareas, for example an area in which through-hole 180 of on-skin sensorassembly 500, 600 resides. In addition, strain relief may be desirableoutside of the encapsulant to reduce wire strain and maintain theposition of sensor 138 against the mounting surface.

An additional or alternative solution that not only holds sensor 138 asplaced by such a placement gripper while epoxy is being cured, but alsoprevents wicking of the epoxy along sensor 138 while simultaneouslyproviding strain relief to sensor 138 is described in connection withFIGS. 22-27 and 40A-41 below. Pockets of varying geometry, configured tohold a predetermined amount of epoxy for securing sensor 138, areutilized in combination with step-up, step-down or flush transitionsfrom the pockets to adjacent areas, the transitions specificallydesigned as “fluidic stops” that prevent epoxy deposited in the pocketsfrom bleeding, wicking or otherwise running beyond the boundaries of thepocket and into the adjacent areas or onto the sensor are described. Insome embodiments, the pockets, transitions, and adjacent areas may beformed utilizing a low-pressure molding process or any other suitableprocess. In some embodiments, the pockets and their adjacent areas arecontinuous with respect to one another, e.g., the adjacent areas aredisposed immediately adjacent to their respective pocket withoutfeatures, other than the transitions, therebetween. In some embodiments,the epoxy is composed of a non-conductive material. In some embodiments,the epoxy is composed of a conductive material.

FIG. 22 shows a perspective view of a plurality of pockets havingvarying geometries in combination with step-up, step-down or flushtransitions of varying widths to adjacent areas, according to someembodiments. FIG. 23 illustrates a plan view of several examplegeometries for the pockets of FIG. 22. FIG. 24 illustrates a set of sideviews of an example step-up transition as would be viewed along thecut-lines A-A′ in FIG. 22, an example flush transition as would beviewed along the cut-line B-B′ in FIG. 22, and an example step-downtransition as would be viewed along the cut-line C-C′ in FIG. 22. FIG.25 illustrates a set of side views viewed along the cut-lines A-A′, B-B′and C-C′ in FIG. 24, further illustrating an example width “w” of thetransitions and example orientations of the sidewalls of the pocketsand/or adjacent areas. The pockets, transitions and adjacent areas willnow be discussed in combination with FIGS. 22-25.

FIG. 22 illustrates a plurality of pockets 2200 a-2200 p, each pockethaving a corresponding adjacent area on either side. Each of the pockets2200 a-220 p are illustrated as having a different combination of pocketgeometry, type of transition between the pocket and the adjacent areas,and transition widths “w.” The callouts “E,” “F” and “P” in FIG. 22illustrate several of the aspects of these different combinations, whichwill be described in more detail in connection with FIGS. 23-25. Itshould be understood that any of the pockets, adjacent areas, and/ortransitions therebetween, described in connection with at least FIGS.22-25, can be implemented into the housings of any of wearableassemblies 500, 600 as previously described in connection with at leastFIGS. 5A-6C.

As shown in callout “E,” a first adjacent area 2210 e is disposed at afirst side of pocket 2200 e and a second adjacent area 2220 e isdisposed at a second side of pocket 2200 e opposite the first side.Callout “E” further illustrates a first transition 2204 e between pocket2200 e and the first adjacent area 2210 e and a second transition 2206 ebetween pocket 2200 e and the second adjacent area 2220 e. First andsecond transitions 2204 e, 2206 e may comprise the structure and/orgeometry that separates respective bases 2215 e, 2225 e of first andsecond adjacent areas 2210 e, 2220 e from a base 2205 e of pocket 2200e. In callout “E” the first and second transitions 2204 e, 2206 e areshown as “step-down” transitions, so-called because respective bases2215 e, 2225 e of each of adjacent areas 2210 e, 2220 e are disposed ata lower height than base 2205 e of pocket 2200 e by an amount “h.” Anexample value for “h” is 0.5 mm, however, the present disclosure is notso limited and any suitable value for “h” is also contemplated. Each ofthe transitions 2204 e, 2206 e is also shown as having a width “w.” Insome embodiments, width “w” may be defined as a separation distancebetween sidewalls of 2208 e of a particular transition 2204 e, 2206 e.An example range of values for “w” is 0.5-2.0 mm, however, the presentdisclosure is not so limited and any suitable value or range for “w” isalso contemplated. The first adjacent area 2210 e has sidewalls 2212 e.The second adjacent area 2220 e has sidewalls 2222 e, the pocket hassidewalls 2202 e, and the sidewalls at the first and second transitions2204 e, 2206 e are illustrated as 2208 e. Callout “E” furtherillustrates a cut-line A-A′ along which the “step down” view illustratedin FIG. 24 may correspond.

Callout “P” illustrates pocket 2200 p having a first transition 2204 pto a first adjacent area 2210 p and a second transition 2206 p to asecond adjacent area 2220 p. The arrangement in callout “P” issubstantially similar to the arrangement in callout “E” except first andsecond transitions 2204 p, 2206 p are illustrated as “flush”transitions, so-called because respective bases 2215 p, 2225 p of eachof adjacent areas 2210 p, 2220 p are disposed at the same height as abase 2205 p of pocket 2200 p. Callout “P” further illustrates a cut-lineB-B′ along which the “flush” view illustrated in FIG. 24 may correspond.

Callout “F” illustrates pocket 2200 f having a first transition 2204 fto a first adjacent area 2210 f and a second transition 2206 f to asecond adjacent area 2220 f. The arrangement in callout “F” issubstantially similar to the arrangement in callout “E” except first andsecond transitions 2204 f, 2206 f are illustrated as “step-up”transitions, so-called because respective bases 2215 f, 2225 f of eachof adjacent areas 2210 f, 2220 f are disposed at an elevated heightcompared to a base 2205 f of pocket 2200 f by an amount “h.” An examplevalue for “h” is 0.5 mm, however, the present disclosure is not solimited and any suitable value for “h” is also contemplated. Callout “F”further illustrates a cut-line C-C′ along which the “step up” viewillustrated in FIG. 24 may correspond.

As illustrated in FIG. 23, such pockets may have any one of severalgeometries. In some embodiments, a substantially rectangular pocket 2300a may be utilized. The sidewalls of rectangular pocket 2300 a are shownas substantially planar such that they meet one another to form sharp,angled corners.

In some other embodiments, a substantially rounded rectangular pocket2300 b may be utilized. Portions of the sidewalls of rounded rectangularpocket 2300 b are shown as substantially planar, while other portions ofthe sidewalls, connecting the substantially planar portions, are curvedsuch that sharp, angled corners are not formed. Pockets 2200 a, 2200 b,2200 e, 2200 f, 2200 j, 2200 k and 2200 p of FIG. 22 are illustrated ashaving such a rounded rectangular geometry.

In yet other embodiments, a substantially triangular or diamond-shapedpocket 2300 c may be utilized. The sidewalls of triangular ordiamond-shaped pocket 2300 b are shown as substantially planar such thatthey meet one another to form sharp, angled corners. Pockets 2200 c,2200 d, 2200 g, and 2200 h of FIG. 22 are illustrated as having such atriangular or diamond-shaped geometry.

In yet other embodiments, a substantially rounded triangular ordiamond-shaped pocket (not shown) may be utilized. Similar to therounded rectangular pocket 2300 b, portions of the sidewalls of roundedtriangular or diamond-shaped pocket can be substantially planar, whileother portions of the sidewalls, connecting the substantially planarportions, are curved such that sharp, angled corners are not formed.

In yet other embodiments, a substantially polygonal pocket 2300 d may beutilized. The sidewalls of polygonal pocket 2300 d are shown assubstantially planar such that they meet one another to form sharpcorners. Pockets 2200 m and 2200 n of FIG. 22 are illustrated as havingsuch a polygonal geometry.

In yet other embodiments, a substantially rounded polygonal pocket (notshown) may be utilized. Similar to the rounded rectangular pocket 2300b, portions of the sidewalls of rounded polygonal pocket can besubstantially planar, while other portions of the sidewalls, connectingthe substantially planar portions, are curved such that sharp, angledcorners are not formed.

In addition, although the above geometries have been described inconnection with the pockets themselves, the present disclosure alsocontemplates that such geometries may be applied to any of the adjacentareas as well. For example, while the adjacent areas illustrated in FIG.22 are shown as having rounded square or rectangular geometries, anyother suitable geometry, as described above or elsewhere in thisdisclosure, may also be applied to the adjacent areas, including anysuitable variable shape as a particular context may require or desire.

As illustrated in FIG. 24, pockets may also have any one of severaltypes of transitions to adjacent areas, e.g., fluidic stops. Forexample, the “Step Down” embodiment shows a sidewall 2412 a of a firstadjacent area 2410 a, a sidewall 2402 a of a pocket 2400 a, a sidewall2422 a of a second adjacent area 2420 a, and sidewalls 2408 a at firstand second transition areas 2404 a, 2406 a. Respective bases 2415 a,2425 a of first and second adjacent areas 2410 a, 2420 a are illustratedas disposed at a lower height than a base 2405 a of pocket 2400 a by anamount “h.” An example value for “h” is 0.5 mm, however, the presentdisclosure is not so limited and any suitable value for “h” is alsocontemplated. As illustrated, when epoxy 2430 a is disposed on base 2405a of pocket 2400 a, first and second step-down transitions 2404 a and2406 a can inhibit or prevent epoxy 2430 a from running into first andsecond adjacent areas 2410 a, 2420 a due in part to the surface tensionand surface energy of epoxy 2430 a causing a downward-inflectingmeniscus 2432 a to form at first and second transitions 2404 a, 2406 a,which adheres to the edges of first and second transitions 2404 a, 2406a. In some embodiments, the step-down height “h,” as well as, in somecases the width “w” of transitions 2404 a, 2406 a, and/or the area orvolume of pocket 2400 a, may depend not only on the predetermined amountof epoxy 2430 a applied, but also on the specific viscosity, surfaceenergy and/or surface tension characteristics between epoxy 2430 a,surrounding environment, and the surfaces of the pocket, sensor,dispensing tip, or any other contacting surfaces or fluids. Otherfactors include the surrounding geometry of the pocket and thesurrounding environment (e.g., materials, temperature, or humidity.)This adhering effect of such “step down” transitions and its inhibitionor prevention of epoxy 2430 a running may run contrary to conventionalwisdom, which could expect that such a “step down” transition would notadequately inhibit or prevent epoxy 2430 a from running into first andsecond adjacent areas 2410 a, 2420 a. FIG. 6B and FIG. 30A bothillustrate an example of step down transitions.

The “flush” embodiment of FIG. 24 shows a sidewall 2412 b of a firstadjacent area 2410 ab, a sidewall 2402 b of a pocket 2400 b, a sidewall2422 b of a second adjacent area 2420 b, and sidewalls 2408 b at firstand second transition areas 2404 a, 2406 b. Respective bases 2415 b,2425 b of first and second adjacent areas 2410 b, 2420 b are illustratedas disposed at the same height as a base 2405 b of pocket 2400 b. Asillustrated, when epoxy 2430 b is disposed on base 2405 b of pocket 2400b, first and second flush transitions 2404 b and 2406 b can preventepoxy 2430 b from running into first and second adjacent areas 2410 b,2420 b due in part to the surface tension and surface energy of epoxy2430 b causing a meniscus 2432 b to form at first and second transitions2404 a, 2406 b. In addition, interactions between epoxy 2430 b andtransition sidewalls 2408 b and the width “w” of the transitions (aswill be described in more detail in connection with the orthogonal sideviews of FIG. 25) can also affect the tendency of epoxy 2430 b to beretained within pocket 2400 b by transitions 2404 b, 2406 b, withrelatively narrower widths “w” potentially providing better retention ofepoxy 2430 b within pocket 2400 b. This adhering effect of such “flush”transitions and its inhibition or prevention of epoxy 2430 b running mayrun contrary to conventional wisdom, which could expect that such a“flush” transition would not adequately inhibit or prevent epoxy 2430 bfrom running into first and second adjacent areas 2410 b, 2420 b.

The “step-up” embodiment of FIG. 24 shows a sidewall 2412 c of a firstadjacent area 2410 c, a sidewall 2402 c of a pocket 2400 c, a sidewall2422 c of a second adjacent area 2420 c, and sidewalls 2408 c at firstand second transition areas 2404 a, 2406 c. Respective bases 2415 b,2425 b of first and second adjacent areas 2410 c, 2420 c are illustratedas disposed at an elevated height “h” compared to a base 2405 c ofpocket 2400 c by an amount “h.” An example value for “h” is 0.5 mm,however, the present disclosure is not so-limited and any suitable valuefor “h” is also contemplated. As illustrated, when epoxy 2430 c isdisposed on base 2405 c of pocket 2400 c, first and second step-uptransitions 2404 c and 2406 c can prevent epoxy 2430 c from running intofirst and second adjacent areas 2410 c, 2420 c. However, the surfacetension and surface energy of epoxy 2430 c can cause anupward-inflecting meniscus 2432 c to form at first and secondtransitions 2404 a, 2406 c and at the step-up. Retention of epoxy 2430 cwithin pocket 2400 c may be most effective where the height “h” of thestep-up exceeds a height of upward-inflecting meniscus 2432 c, since thesurface tension and surface energy of epoxy 2430 c can cause epoxy 2430c to creep along the top portion of meniscus 2432 c and into adjacentareas 2410 c, 2420 c if upward-inflecting meniscus 2432 c reaches thelevel of bases 2415 c, 2425 c of either of adjacent areas 2410 c, 2420c. Accordingly, the step-up height “h,” as well as, in some cases thewidth “w” of transitions 2404 c, 2406 c, the area or volume of pocket2400 c, may depend not only on the predetermined amount of epoxy 2430 capplied, but also on the specific viscosity, surface energy and/orsurface tension characteristics between epoxy 2430 c, surroundingenvironment, and the surfaces of the pocket, sensor, dispensing tip, orany other contacting surfaces or fluids. Other factors include thesurrounding geometry of the pocket and the surrounding environment(e.g., materials, temperature, or humidity.) This creeping effect ofepoxy 2430 b when utilized with such “step up” transitions havinginsufficient height “h” and its limited ability to inhibit or preventepoxy 2430 c from running into adjacent areas may run contrary toconventional wisdom, which could expect that such a “step up” transitionwould adequately inhibit or prevent epoxy 2430 c from running into firstand second adjacent areas 2410 c, 2420 c even if a height ofupward-inflecting meniscus 2432 c did reach the transition height “h.”

As illustrated in FIGS. 22 and 25, transitions between pockets 2400 a-cand adjacent areas 2410 a-c, 2420 a-c may also have varying widths “w”between the transition's sidewalls. An example range of values for “w”is 0.5-2.0 mm, however, the present disclosure is not so-limited and anysuitable value for “w” is also contemplated. For example, the first rowof pockets 2200 a, 2200 b, 2200 c and 2200 d of FIG. 22 are shown ashaving a relatively narrow transition width “w” of approximately 0.5 mm;the second row of pockets 2200 e, 2200 f, 2200 g and 2200 h and 2200 pof FIG. 22 are shown as having a relatively moderate transition width“w” of approximately 1.0 mm, greater than the above-described relativelynarrow transition width; and the third row of pockets 2200 j, 2200 k,2200 m and 2200 n of FIG. 22 are shown as having a relatively widetransition width “w” of approximately 2.0 mm, greater than either of theabove-described relatively narrow or relatively moderate transitionwidths. FIG. 25 shows transition widths “w” which may correspond to anydesired and/or suitable width(s) capable of retaining epoxy in thepocket. Furthermore, transitions on either side of a pocket may havedifferent widths from one another. For example, a first width of a firsttransition between a pocket and a first adjacent area can be greaterthan or less than a second width of a second transition between thepocket and a second adjacent area.

As further illustrated in FIG. 25, in some embodiments, adjacent areasidewalls 2422 a-c, pocket sidewalls (not shown in FIG. 25) and/ortransition sidewalls 2408 a-c may be substantially perpendicular totheir respective bases 2415 a-c, 2425 a-c, 2405 a-c, as illustrated bythe solid vertical lines at the sidewalls. In yet other embodiments,adjacent area sidewalls 2422 a-c, pocket sidewalls (not shown in FIG.25) and/or transition sidewalls 2408 a-c may be slightly sloped orangled from such a substantially perpendicular orientations to theirrespective bases 2415 a-c, 2425 a-c, 2405 a-c, as illustrated by thedashed lines at the sidewalls.

While the embodiments illustrated in FIGS. 22-25 show the same types oftransitions on either side of a particular pocket, the presentdisclosure is not so-limited and any combinations of step-up, step-downand flush transitions may be used on any pocket. For example, a firsttransition to a first side may be any of a step-up, flush or step-downtransition, while the second transition on another side of the pocketmay be any of a step-up, flush or step-down transition.

In addition, any number of pockets and or adjacent areas may be utilizedin the same wearable assembly 600, on the same housing 622 for such awearable assembly 600, on the same electronics assembly substrate 630 oreven to secure different portions of the same sensor 138. For example,in some embodiments, two or more pockets may be formed in proximity toone another and each may have its own respective adjacent areas or,alternatively, adjacent pockets may share an intervening adjacent areafrom different sides. Some embodiments further contemplate more or fewerthan the two adjacent areas per pocket described.

FIG. 26 illustrates a photograph of a first arrangement comprising apocket 2600 a, a first step-down transition 2604 a to a first adjacentarea 2610 a, and a second step-down transition 2606 a to a secondadjacent area 2620 a. As pictured, epoxy 2630 a adhering sensor 138 wassubstantially contained within pocket 2600 a. As previously described inconnection with FIG. 24, first and second step-down transitions 2604 a,2606 a can inhibit or prevent epoxy 2630 a from running into first andsecond adjacent areas 2610 a, 2620 a due in part to the surface tensionand surface energy of epoxy 2630 a causing a downward-inflectingmeniscus to form at first and second transitions 2604 a, 2606 a, whichadheres to the edges of first and second transitions 2604 a, 2606 a.FIG. 26 further illustrates a second arrangement, below the first,comprising a pocket 2600 b, a first step-up transition 2604 b to a firstadjacent area 2610 b, and a second step-up transition 2606 b to a secondadjacent area 2620 b. As pictured, epoxy 2630 b adhering sensor 138crept beyond transitions 2604 b, 2606 b and into adjacent areas 2610 b,2620 b.

It is contemplated that the failure of the second arrangement to retainepoxy 2630 b within pocket 2600 b may have been due to the height oftransitions 2604 b, 2606 b being insufficient such that anupward-inflecting meniscus of epoxy 2630 b at step-up transitions 2604b, 2606 b reached the bases of first and second adjacent areas 2610 b,2610 b, causing epoxy 2630 b to creep along the tops of the meniscus andoverflow into adjacent areas 2610 b, 2620 b. Once epoxy 2630 b began torun, sensor 138 may have provided a further surface along which epoxy2630 b could overflow.

In some embodiments, flush or step up transitions with insufficientheight “h,” as previously described in connection with FIGS. 22-26 canbe purposefully implemented between one or more pockets and one or moreadjacent areas in order to intentionally overflow epoxy onto, forexample, certain parts of sensor 138 (e.g., reference electrode 212). Insome of those embodiments, a step-down transition may also be utilizedbetween the one or more pockets and other adjacent areas in order tointentionally inhibit or prevent overflow of the epoxy onto, forexample, other parts of sensor 138 (e.g., working electrode 211).

FIG. 27 shows a plan view (top) and a side cutaway view (bottom) alongcut-line A-A′ of an arrangement utilizing pockets 2700 a, 2700 b andadjacent areas 2710 a, 2710 b, 2720 similar to that described above inconnection with FIGS. 22-26 for securing a sensor 138 directly toelectronics substrate assembly 630, and further utilizing an optionalpost 2712 for centering sensor 138, according to some embodiments. Inthe figure, a first pocket 2700 a and a second pocket 2700 b are eachillustrated as having step-down transitions on either side to adjacentareas 2710 a, 2710 b, 2720. Adjacent area 2710 a is shown as a firstadjacent area for first pocket 2700 a, adjacent area 2710 b is shown asa first adjacent area for second pocket 2700 b, and adjacent area 2720is shown as a second adjacent area for each of first and second pockets2700 a, 2700 b. Contact 324 is shown in adjacent area 2710 a, contact334 is shown in adjacent area 2720, and through-hole 180 is shown inadjacent area 2710 b. Adjacent area 2710 b is further shown to have post2712 disposed therein. While specific orientations and placements of theabove pockets, adjacent areas, contacts and posts are given, they are tobe construed as examples and not limiting of this disclosure, whichcontemplates any arrangements of all or a subset of the above describedfeatures alone or in combination with any other features described inthis disclosure or otherwise.

Conductive epoxy or other suitable conductive material is disposed oncontacts 324, 334 for electrically coupling respective portions ofsensor 138 thereto (e.g., contacts 211 b and 212 b, respectively aspreviously described in connection with at least FIG. 3D).

As further illustrated in FIG. 27, and previously described inconnection with FIGS. 22-26, epoxy is disposed within pockets 2700 a,2700 b and is retained therein by virtue of the step-down transitions,e.g., fluidic stops, between pockets 2700 a, 2700 b and adjacent areas2710 a, 2710 b, 2720. Similarly, epoxy can be disposed on a top surfaceof post 2712, which also has step-down features at a transition from itscircumferential edges and the base of adjacent area 2710 b within whichpost 2712 is disposed that retains the epoxy on the top surface of post2712. Accordingly, when sensor 138 is placed on the arrangement of FIG.27, respective portions of sensor 138 can contact and be secured by notonly the conductive epoxy disposed on contacts 324, 334, but also by theUV-curable epoxy disposed within pockets 2700 a, 2700 b and on post2712. In addition, due to the substantially symmetrical geometry andrelatively smaller top surface of post 2712, the surface energy andsurface tension of the epoxy disposed on the top surface of post 2712will tend to exert a small centering force on the portion of sensor 138disposed thereon, maintaining or self-correcting alignment of sensor138.

While post 2712 is shown as having a substantially circular geometry,the present disclosure is not so-limited and post 2712 may have anysuitable geometry, though symmetrical geometries as viewed through acenterline defined by the direction of extension of sensor 138 acrossthe top surface of post 2712 may best allow the surface energy and/orsurface tension of the epoxy disposed thereon to provide symmetricalforces that center the portion of sensor 138 resting on post 2712.

In addition, or alternative, to the use of step-up, step-down, and/orflush transitions as previously described in connection with FIGS.22-27, the present disclosure also contemplates forming bases of theadjacent areas to have different surfaces energies compared to thepocket to thereby prevent the epoxy from bleeding to adjacent areas.FIG. 40A illustrates a perspective view of a pocket 4000 a with a base4005 a having a first surface energy, adjacent areas 4010 a, 4020 a withrespective bases 4015 a, 4025 a having a different surface energy fromthe first surface energy of pocket base 4005 a. In some embodiments,bases 4015 a, 4025 a can have a same, second surface energy that isdifferent from the first surface energy of pocket base 4005 a. In someother embodiments, base 4015 a can have the second surface energy, whilebase 4025 a can have a third surface energy different from the first andsecond surface energies. In some embodiments, the first, second and/orthird surface energies of pocket base 4005 a and adjacent area bases4015 a, 4025 a can be determined, set and/or modified by applying one ormore of, e.g., a plasma etch, a Teflon tape, a relatively low-surfaceenergy tape, a different surface texture, grooves or any other suitablematerials or features to one or more of pocket base 4005 a and adjacentarea bases 4015 a, 4025 a. FIG. 40A further illustrates step-downtransitions 4004 a and 4006 a to respective adjacent areas 4010 a, 4020a.

FIG. 40B illustrates a pocket 4000 b with a base 4005 b having a firstsurface energy, adjacent areas 4010 a, 4020 b with respective bases 4015a, 4025 b having a different surface energy from the first surfaceenergy of pocket base 4005 b. In some embodiments, bases 4015 a, 4025 bcan have a same, second surface energy that is different from the firstsurface energy of pocket base 4005 b. In some other embodiments, base4015 b can have the second surface energy, while base 4025 b can have athird surface energy different from the first and second surfaceenergies. In some embodiments, the first, second and/or third surfaceenergies of pocket base 4005 b and adjacent area bases 4015 a, 4025 bcan be determined, set and/or modified by applying one or more of, e.g.,a plasma etch, a Teflon tape, a relatively low-surface energy tape, adifferent surface texture, grooves or any other suitable materials orfeatures to one or more of pocket base 4005 b and adjacent area bases4015 a, 4025 b. In contrast to FIG. 40A, FIG. 40B further illustratesflush transitions 4004 b and 4006 b to respective adjacent areas 4010 a,4020 b.

The differing surface energies at the transitions 4004 a-b, 4006 a-b cancause epoxy disposed within pockets 4000 a-b to form a down-wardinflecting meniscus at transitions 4004 a-b, 4006 a-b, respectively,similar to that previously described in connection with at least FIGS.24 and 25, thereby preventing the epoxy from undesirably creeping frompocket base 4005 a-b to adjacent areas 4010 a-b, 4020 a-b.

FIG. 41 illustrates a side cutaway view of a pocket 4100 havingstep-down transitions 4104, 4106 to respective adjacent areas 4110,4120, and further including an additional step-down transition 4152 toan additional adjacent area 4150 for preventing epoxy from bleeding toadjacent areas 4110, 4120, according to some embodiments.

In some embodiments, in addition to, or in the alternative of, utilizingone or more adjacent areas as previously described in connection with atleast FIGS. 22-27, one or more adjacent areas 4150 may be disposedimmediately adjacent to and/or abutting a sidewall 4108 of a pocket 4100and configured to accept at least an excess portion of epoxy 4130disposed within pocket 4100, thereby preventing epoxy 4130 from creepinginto at least one of adjacent areas 4110, 4120.

For example, FIG. 41 shows pocket 4100 having base 4105 and sidewalls4108 having a top surface 4109, an adjacent area 4110 having a base4115, a transition 4104 between base 4115 and base 4105, an adjacentarea 4120 having a base 4125, and a transition 4106 between base 4125and base 4105. Transitions 4104, 4106 are shown as “step down”transitions as previously described in connection with FIGS. 22-27.However, the present disclosure is not so limited and one or both oftransitions 4104, 4106 can alternatively be “flush” or “step up”transitions as previously described.

While transitions 4104, 4106 may be configured to prevent an epoxy 4130,disposed within pocket 4100 on base 4105, from wicking and/or creepinginto adjacent areas 4110, 4120, if pocket 4100 is sufficientlyoverfilled with epoxy 4130, the adhering character of one or both oftransitions 4104, 4106 with respect to epoxy 4130, in isolation, may beinsufficient to prevent epoxy 4130 from wicking and/or creeping intoadjacent areas 4110, 4120. Accordingly, by providing adjacent area 4150with a base 4155 disposed at a lower elevation than top surface 4109 ofsidewall 4108 of pocket 4100 and a transition 4152 between top surface4109 of sidewall 4108 of pocket 4100 and base 4155, adjacent area 4150can be configured to accept at least an excess portion of epoxy 4130disposed within pocket 4100, thereby preventing epoxy 4130 from creepinginto at least one of adjacent areas 4110, 4120. In such embodiments,step down transition 4152 may be specifically configured to allow excessportions of epoxy 4130 to flow, creep and/or wick into adjacent area4150 and not into adjacent areas 4110, 4120. In some embodiments,transition 4152 may alternatively be configured to cause epoxy 4130disposed within pocket 4100 to adhere to transition 4152 and therebyinhibit epoxy 4130 from creeping into adjacent area 4150.

In any of the above embodiments featuring a pocket and an adjacent area,an additional conductive adhesive material, such as a conductive epoxy,may be implemented to mechanically and electrically connect sensor 138to contacts of electronics assembly substrate 630. For example, sensor138 may be affixed to a pocket as described above, and affixed andelectrically connected to electronics assembly substrate 630 asdescribed in FIGS. 21A-21D. In some embodiments, sensor 138 is firstaffixed to a pocket and then affixed to the electronics assemblysubstrate. In other embodiments, sensor 138 is first affixed to theelectronics assembly substrate and then affixed to a pocket.

Utilization of a Passivation Layer on a Connected Sensor in a Pocket ofa Wearable Transmitter

Wearable analyte sensor transmitter assemblies 500, 600 as previouslydescribed may be vulnerable to leakage currents in the circuitrydisposed therein as a consequence of undesirable moisture ingress. Suchleakage currents may be detected during long-term heat and humiditytesting of the analog front end (AFE) of such transmitters. Accordingly,it may be desirable to prevent moisture from interfering with the signalreceived by the AFE. An example solution is described in connection withFIGS. 28A-28C below.

FIG. 28A shows a perspective view of wearable assembly 600 comprisinglower housing 622 having aperture 626, sensor 138 having at least aportion disposed within aperture 626 and being directly connected toelectronics assembly substrate 630 (not shown in FIGS. 28A-28C) by oneor more conductive contacts (e.g., conductive contacts 324, 334), aspreviously described in FIGS. 6A-6C, for example. FIG. 28A furtherillustrates a dam 2806 separating a first portion of a cavity, formed byaperture 626 and having at least a proximal portion of sensor 138disposed therein, from a second portion of the cavity havingthrough-hole 180 and a medial and/or distal portion of sensor 138. Dam2806 is shown to have a narrow gap 2808 through which sensor 138 isconfigured to pass.

As shown by FIG. 28B, an electrical and moisture passivation layer 2802can be applied to the top surface of at least the proximal portion ofsensor 138 and at least a portion of housing 622 disposed within thefirst portion of the cavity utilizing any suitable method, for example,vacuum deposition, inkjet printing, 3D printing, sputtering, chemicalvapor deposition or any other suitable deposition technique.

Once passivation layer 2802 has been applied, the first portion of thecavity formed by aperture 626 and containing at least the proximalportion of sensor 138 can be filled with an epoxy or other suitablematerial for mechanical fixation and protection of at least the proximalportion of sensor 138. In addition, or in the alternative, to fillingthe first portion of the cavity with epoxy, a cap may be placed overaperture 626, for example, as previously described in connection withFIGS. 7A-10. While FIGS. 28A-28C illustrate dam 2806 being a part oflower housing 622, the present disclosure is not so-limited and such adam may be made a part of a cap that is disposed within, on or overaperture 626, also as previously described in connection with at leastFIGS. 7A-10.

Another passivation technique that may be utilized to prevent orsubstantially reduce moisture ingress to circuitry of wearable 500, 600is shown in FIG. 29. As shown in the figure, lower housing 622 may havea molded geometry configured to receive electronics assembly substrate630. Rather than directly connecting one or more electrical connectionsto electronics assembly substrate 630, a plurality of contacts,conductive trace layers, and passivation layers may be seriallydeposited such that those electrical connections can be made at a levelabove that of electronics assembly substrate 630 while still sealing andprotecting the underlying electronics assembly substrate 630 and/orsensor 138 from moisture ingress.

For example, one or more electrical contacts, conductive pucks or otherconductive structures 2902 a can be deposited at the appropriatelocations on electronics assembly substrate 630. One or more conductivetrace layers 2904 can be deposited on contact(s) 2902 a and on a portionof lower housing 622. In some embodiments, conductive trace layer(s)2904 extend to a greater extent laterally than either or both ofcontact(s) 2902 a and electronics assembly substrate 630. A plurality ofpassivation layers 2906, 2908 can then be deposited over at least aremaining exposed portion of electronics assembly substrate 630 andportions of conductive trace layer(s) 2904, thereby sealing andpassivating electronics assembly substrate 630 and/or sensor 138 frommoisture ingress from the outside environment. In some embodiments,passivation layers 2906, 2908 may comprise different passivatingmaterials from one another, for example, a conformal coating, aUV-curable glue, a sputtered metal (e.g., aluminum), a thin metalcoating, a polymer (e.g., polyethylene), an elastomer, a ceramic or anyother suitable material. One or more electrical contacts, conductivepucks or other conductive structures 2902 b can be deposited at theappropriate exposed locations on conductive trace layer(s) 2904 and oneor more additional conductive trace layers 2912 can be deposited overcontact(s) 2902 b and passivation layer(s) 2906, 2908. In someembodiments, conductive trace layer(s) 2912 extend laterally fromcontact(s) 2902 b such that one or more electrical connections can bemade at a location on conductive trace layer(s) 2912 laterally removedfrom contact(s) 2902 b. One or more additional passivation layers 2914,2916 can then be deposited over the underlying layers to seal andprotect not only the underlying passivation and conductive layers, butalso electronics assembly substrate 630 from mechanical- andmoisture-related damage.

Sealing a Housing Cavity Without UV Epoxy Fill and Encapsulation

In some embodiments it may be desirable to be able to seal a cavity ofhousing 622 and the electronic circuitry disposed therein form moistureingress without having to fill the cavity with a curable epoxy.Accordingly, several solutions are described below in connection withFIGS. 30A-33.

FIG. 30A illustrates a plan view of a wearable assembly 600 including aheat-sealable thermoplastic elastomer 3002 and a mating cap 3004including a heat-sealable thermoplastic elastomer 3006, according tosome embodiments. FIG. 30B illustrates a side cutaway view of wearableassembly 600, as viewed along the cutline A-A′ in FIG. 30A, and matingcap 3004 disposed for securing to wearable assembly 600.

Wearable assembly 600 comprises lower housing 622, including aperture626 that forms a cavity within lower housing 622. A first portion ofthis cavity is configured to house at least a proximal portion of sensor138, while a second portion of this cavity comprises through-hole 180through which a sensor applicator needle is configured to pass.Heat-sealable thermoplastic elastomer 3002 is disposed partially orcompletely around the first portion of the cavity formed by aperture626. As shown in FIG. 30B, heat-sealable thermoplastic elastomer 3002surrounds at least the proximal portion of sensor 138 as placed in thefirst portion of the cavity. Sensor 138 is further shown as beingelectrically connected to electronics assembly substrate 630 and passingthrough a slit (not shown) in heat-sealable thermoplastic elastomer3002, thereby extending into the second portion of the cavity havingthrough-hole 180. While FIG. 30B illustrates electronics sensor assembly630 as being within a same cavity as the proximal portion of sensor 138,the present disclosure is not so limited. Electronics sensor assembly630 can alternatively be disposed within a different cavity withinhousing 622 than the proximal portion of sensor 138 and may be separatedfrom sensor 138 by at least a portion of housing 622, through which oneor more conductive contacts (e.g., contacts 324, 334 of FIG. 3D) canprovide direct electrical connection between sensor 138 and electronicsassembly substrate 630 (see, e.g., FIGS. 6A-6C).

As further shown in FIG. 30B, the heat-sealable thermoplastic elastomer3006 disposed on cap 3004 is configured to abut a portion ofheat-sealable thermoplastic elastomer 3002 adjacent to or abutting thesecond portion of the cavity through which sensor 138 is configured topass when cap 3004 is properly placed. Upon proper placement of cap 3004on lower housing 622 of wearable assembly 600, heat may be applied toheat-sealable thermoplastic elastomers 3002, 3006, for example by laser,to melt heat-sealable thermoplastic elastomers 3002, 3006 againstrespective portions of cap 3004 and lower housing 622, thereby weldingand sealing at least the first portion of the cavity formed by aperture626 that houses at least the proximal portion of sensor 138 frommoisture ingress. Among other advantages, because the seal provided bymelting heat-sealable thermoplastic elastomers 3002, 3006 ismoisture-tight, curable epoxy encapsulation within the cavity (aspreviously described in connection with at least FIGS. 6A-10) is notnecessary and can be eliminated, reducing manufacturing complexity.

Another solution will now be described in connection with FIG. 31 below.FIG. 31 illustrates a side cutaway view of a portion of lower housing622 of wearable assembly 600 and an overmolded cap 3100, according tosome embodiments. As shown, electronic assembly substrate 630 isconfigured to rest within the geometry of lower housing 622. Contacts324, 334 are disposed on electronic assembly substrate 630. Sensor 138is disposed over contacts 324, 334 such that respective portions of thesensor make physical and electrical contact with contacts 324, 334(e.g., respective contacts 211 b and 212 b, as previously described inconnection with at least FIG. 3D). While electronics assembly substrate630 is shown as disposed within a same cavity as at least a proximalportion of sensor 138, the present disclosure is not so limited and atleast a portion of housing 622 can physically separate electronicsassembly substrate 630 from the cavity within which the proximal portionof sensor 138 is disposed (see, e.g., FIGS. 6A-6C). In such embodiments,contacts 324, 334 can extend through the portion of housing 622 thatphysically separates electronics assembly substrate 630 to makeelectrical contact with sensor 138.

FIG. 31 further shows a cap or an overmolded cap 3100 comprising a basematerial 3102, for example polycarbonate, plastic, metal, or any othermaterial with suitable strength to maintain a seal. The overmolded cap3100 further comprises an insulating and sealing material 3104 having aplurality of cavities in which conductive elastomeric pucks 3106 and3108 reside in or fit into. In some embodiments, the cavities and theconductive elastomeric pucks 3106, 3108 may have a substantiallycylindrical shape. However, the present disclosure is not so-limited andany shape is also contemplated. In some embodiments, a portion ofinsulating and sealing material 3104 is disposed directly between facingsurfaces of base material 3102 and conductive elastomeric pucks 3106 and3108. When overmolded cap 3100 is placed over and/or within the cavityof housing 622, conductive elastomeric pucks 3106 and 3108 press againstportions of sensor 138 and contacts 324, 334, thereby securing theportions of sensor 138 to their respective contacts 324, 334. Althoughnot shown, it is contemplated that, in some embodiments, conductiveelastomeric pucks 3106 and 3108 may be disposed adjacent to contacts 324and 334, respectively, and sensor 138 may be disposed adjacent toconductive elastomeric pucks 3106 and 3108 on the side opposite contacts324 and 334. In such embodiments, conductive elastomeric puck 3106 maypress against a first electrode of sensor 138 on one side and pressagainst cap 3100 on the other. Conductive elastomeric puck 3108 maypress against a second electrode of sensor 138 on one side and pressagainst cap 3100 on the other. Further, in other embodiments, conductiveelastomeric pucks 3106 and 3108 may each be composed of two halves, inwhich portions of sensor 138 may reside between the two halves of puck3106 or 3108 or both pair of halves of pucks 3106 and 3108. Further, inother embodiments, it is contemplated that one or more of contacts 324and 334 may have a gap formed within the contact. In such embodiments,at least one of conductive elastomeric pucks 3106 and 3108 may residewithin (e.g. via press fit or friction fit) the gap of either contact324 or 334.

As shown in FIG. 31, insulating and sealing material 3104 is configuredto fill or at least partially fill the cavity contacts 324, 334 and thecontacting portions of sensor wire 138, sealing them from moistureingress. Among other advantages, embodiments according to FIG. 31 canremove curable epoxy dispensing and curing steps, conductive epoxydispensing and curing steps and, potentially, extra strain-relief stepsrelated to sensor 138, thereby reducing manufacturing complexity.

Yet another solution will now be described in connection with FIG. 32below. FIG. 32 illustrates a side cutaway view of a portion of lowerhousing 622 of wearable assembly 600 and an overmolded cap 3200,according to some embodiments. As shown, electronic assembly substrate630 is configured to rest within the geometry of lower housing 622.Contacts 324, 334 are disposed on electronic assembly substrate 630.Sensor 138 is disposed over contacts 324, 334 such that respectiveportions of the sensor make physical and electrical contact withcontacts 324, 334 (e.g., respective contacts 211 b and 212 b, aspreviously described in connection with at least FIG. 3D). Whileelectronics assembly substrate 630 is shown as disposed within a samecavity as at least a proximal portion of sensor 138, the presentdisclosure is not so limited and at least a portion of housing 622 canphysically separate electronics assembly substrate 630 from the cavitywithin which the proximal portion of sensor 138 is disposed (see, e.g.,FIGS. 6A-6C). In such embodiments, contacts 324, 334 can extend throughthe portion of housing 622 that physically separates electronicsassembly substrate 630 to make electrical contact with sensor 138.

FIG. 32 further shows an overmolded cap 3200 comprising a base material3202, for example polycarbonate, plastic, metal, or any other materialwith suitable strength to maintain a seal. Base material 3202 is shownas having a plurality of apertures or holes 3216, 3218 at locationsconfigured to be over and laterally aligned with contacts 324, 334 whenovermolded cap 3200 is properly placed. Overmolded cap 3200 furthercomprises an insulating and sealing material 3204 having a plurality ofcavities 3210, 3212 configured to be disposed directly over contacts324, 334 when overmolded cap 3200 is properly placed. Cavities 3210,3212 are configured to receive respective injections of conductive epoxy3206, 3208 via injection needle through holes 3216, 3218 and throughinsulating and sealing material 3204 along the lines of needle piercelines 3214 after overmolded cap 3200 is properly placed. Accordingly,holes 3216, 3218 are also aligned laterally with first and secondcavities 3206, 3208. Moreover, as shown in the figure, at least aportion of sealing material 3204 physically isolates first hole 3216from first cavity 3210 and second hole 3218 from second cavity 3212. Insome embodiments, cavities 3210, 3212 and conductive epoxy injections3206, 3208 may have substantially conical shapes. However, the presentdisclosure is not so-limited and any shape is also contemplated.

When overmolded cap 3200 is placed over electronic assembly substrate630, cavities 3210, 3212 align directly over contacts 324, 334.Insulating and sealing material 3204 presses against portions of sensor138 and contacts 324, 334, thereby holding the portions of sensor 138 totheir respective contacts 324, 334, substantially sealing cavities 3210,3212. Accordingly, when a needle is pressed through insulating andsealing material 3204 at apertures 3216, 3218 along needle pierce lines3214 until the tip of the needle breaks through into cavities 3206,3208, and conductive epoxy 3206 and 3208 is subsequently injected intocavities 3206, 3208, conductive epoxy 3206 and 3208 is contained withincavities 3206, 3208 eliminating the potential for undesirable shortingif conductive epoxy 3206 and 3208 were otherwise allowed to overflowlaterally substantially beyond contacts 324, 334. In addition, in someembodiments a conductive epoxy that does not require heating to cure canbe utilized to reduce heat exposure and related damage to sensor 138.Insulating and sealing material 3204 further seals contacts 324, 334 andthe contacting portions of sensor 138 from moisture ingress.

Among other advantages, embodiments according to FIG. 32 can removecurable epoxy dispensing and curing steps and, potentially, extrastrain-relief steps related to sensor 138, thereby reducingmanufacturing complexity.

Methods of Manufacture Related to the Above-Described Embodiments

Several example methods of fabricating an analyte sensing apparatusand/or housing having an analyte sensor directly connected to a printedcircuit board of a wearable transmitter assembly without the utilizationof a sensor carrier are provided below in connection with FIGS. 33-37.

The methods disclosed herein comprise one or more steps or actions forachieving the described methods. The method steps and/or actions may beinterchanged with one another without departing from the scope of theclaims. In other words, unless a specific order of steps or actions isspecified, the order and/or use of specific steps and/or actions may bemodified without departing from the scope of the claims.

An example method 3300 for fabricating an analyte sensing apparatus willnow be described in connection with FIG. 33 below. Method 3300 maycorrespond at least to the previous description in connection with FIGS.7A-10 and 28A-29.

Block 3302 includes forming a housing comprising an aperture thatdefines a cavity having a first portion and a second portion in thehousing. For example, as previously described in connection with FIGS.6A-10, lower housing 622 can be formed comprising aperture 626 thatdefines cavity 750 having first portion 752 and second portion 754 inlower housing 622.

Block 3304 includes disposing a first conductive contact and a secondconductive contact in the first portion of the cavity. For example,first conductive contact 324 and second conductive contact 334 can bedisposed in first portion 752 of cavity 752.

Block 3306 includes electrically coupling a first electrode of ananalyte sensor to the first conductive contact. For example, firstelectrode 211 b of analyte sensor 138 can be directly electricallycoupled to first conductive contact 324.

Block 3308 includes electrically coupling a second electrode of theanalyte sensor to the second conductive contact. For example, secondelectrode 212 b of analyte sensor 138 can be directly electricallycoupled to second conductive contact 334.

Block 3310 includes forming a cap comprising a first portion and asecond portion, a dam disposed on a side of the cap configured to facethe aperture, a shelf adjacent to the dam, and a compliant componentdisposed on the shelf. For example, as previously described inconnection with FIGS. 7A-7C and 9, cap 700, 900 can be formed to includefirst portion 710, 910 and second portion 720, 920, dam 730, 930disposed on a side of cap 700, 900 configured to face aperture 626,shelf 732 adjacent to dam 730, and compliant component 740, 940 disposedon shelf 732.

As previously described in connection with FIGS. 7A-7C, first portion710 of cap 700 and second portion 720 of cap 700 can be coplanar andformed of a single piece. As previously described in connection withFIG. 9, first portion 910 of cap 900 can extend along a first plane,second portion 920 of cap 900 can extend along a second plane differentfrom the first plane, dam 930 can comprise at least a portion of cap 900that extends between the first plane and the second plane and connectsfirst portion 910 of cap 900 with second portion 920 of cap 900, and atleast some of second portion 920 of cap 900 can comprise the shelf onwhich compliant component 940 rests.

Block 3312 includes fitting the cap on or within the aperture such thatthe first portion of the cap is disposed over the first portion of thecavity, the dam physically divides the first portion of the cavity fromthe second portion of the cavity, and the compliant component pressesagainst a portion of the analyte sensor and against a surface of thehousing within the cavity, thereby sealing the first portion of thecavity from the second portion of the cavity. For example, cap 700, 900can be fit on or within aperture 626 such that first portion 710, 910 ofcap 700, 900 is disposed over first portion 752 of cavity 750, dam 730,930 physically divides first portion 752 of cavity 750 from secondportion 754 of cavity 750, and compliant component 740, 940 pressesagainst a portion of analyte sensor 138 and against a surface of lowerhousing 622 within cavity 750, thereby sealing first portion 752 ofcavity 750 from second portion 754 of cavity 750.

In some embodiments, method 3300 may further comprise disposingelectronics assembly substrate 630 within housing 622, wherein firstconductive contact 324 and second conductive contact 334 extend fromelectronics assembly substrate into first portion 752 of cavity 750.

In some embodiments, first portion 710, 910 of cap 700, 900 can comprisefirst hole 702, 902 and method 3300 can further comprise, for example,depositing encapsulating sealant 628, 928 into first portion 752 ofcavity 750 through first hole 702, 902, thereby sealing at least aportion of analyte sensor 138 from moisture ingress.

In some embodiments, first portion 710, 910 of cap 700, 900 can comprisesecond hole 704, 904, and method 3300 can further comprise, for example,allowing excesses of encapsulating sealant 628, 928 to flow out of firstportion 752 of cavity 750 through second hole 704, 904.

In some embodiments, dam 730, 930 can contact a portion of lower housing622 within cavity 750. In some embodiments, compliant component 740, 940can comprise a foam or a rubber material. In some embodiments, compliantcomponent 740, 940 can prevent encapsulating sealant 628, 928 fromflowing into second portion 754 of cavity 750.

In some embodiments, cap 700 can comprise second portion 720, 920disposed over second portion 754 of cavity 750. In some otherembodiments, cap 900 can comprise second portion 920 disposed adjacentto second portion 754 of cavity 750. In some embodiments, second portion710 of cap 700 can comprise slot 722, and method 3300 can furthercomprise, for example, causing at least a portion of analyte sensor 138to pass through slot 722.

In some embodiments, an outside-facing surface of cap 700, 900 can fitflush with an outside-facing surface of lower housing 622. In some otherembodiments, the outside-facing surface of cap 700, 900 can fit in arecessed position compared to the outside-facing surface of lowerhousing 622. In yet other embodiments, cap 700, 900 can be disposed onthe outside-facing surface of lower housing 622.

In some embodiments, method 3300 can further comprise, for example,securing cap 700, 900 to lower housing 622 utilizing at least one of atoe feature, a snap feature, a friction-fit feature, and apressure-sensitive adhesive.

In some embodiments, cap 700, 900 comprises a material substantiallytransparent to ultra-violet radiation, and method 3300 can furthercomprise, for example, curing encapsulating sealant 628, 928 by exposingencapsulating sealant 628, 928 to the ultra-violet radiation through cap700, 900.

In some embodiments, method 3300 can further involve the fabricationand/or application of an adhesive patch as previously described inconnection with FIGS. 8A-8C. Method 3300 can further comprise, forexample, securing cap 700, 900 to lower housing 622 utilizing firstadhesive portion 902 of adhesive patch 126, adhesive patch 126 furthercomprising second adhesive portion 804 configured to adhere firstadhesive portion 802 and wearable assembly 600 to a skin of a host.Method 3300 can further comprise, for example, securing first adhesiveportion 802 of adhesive patch 126 to cap 700, 900 before cap 700, 900 isfit on or within aperture 626 of lower housing 622. First adhesiveportion 802 can comprise at least a hole 880 a configured tosubstantially coincide with at least one hole within cap 700, 900 whencap 700, 900 is secured to first adhesive portion 802 of adhesive patch126. Second adhesive portion 804 can comprise at least a hole 880 bconfigured to substantially coincide with at least one hole within cap700, 900 when cap 700, 900 is secured to second adhesive portion 804 ofadhesive patch 126.

In some embodiments, as described in connection with FIGS. 28A-29,method 3300 can further comprise, for example, depositing at least onepassivation layer 2802, 2906, 2908 over at least a portion of analytesensor 138, thereby preventing moisture ingress to the portion of sensor138. Method 3300 can further comprise depositing one or more conductivetraces 2904, 2912 on the passivation layer(s) 2906, 2908, andelectrically coupling conductive traces 2904, 2912 to one or more offirst conductive contact 324 and second conductive contact 334, e.g.,one or both potentially illustrated as contact 2902 a in FIG. 29.

An example method 3400 for fabricating an analyte sensing apparatus willnow be described in connection with FIG. 34 below. Method 3400 maycorrespond at least to the previous description in connection with FIGS.11A-20.

Block 3402 includes fabricating a housing. For example, lower housing622 can be formed as previously described in connection with FIGS.11A-20.

Block 3404 includes disposing an electronics assembly substrate withinthe housing. For example, electronics assembly substrate 630 can bedisposed within housing 622.

Block 3406 includes coupling an analyte sensor comprising an elongatedbody having at least a first bend to at least one of the housing and theelectronics assembly substrate. For example, analyte sensor 138 can becoupled to at least one of housing 622 and electronics assemblysubstrate 630 and comprises an elongated body having at least a firstbend 1102 a-c, 1202, 1302, 1402, 1502, 1602, 1702, 1802, 1902 or 2002,as previously described in connection with FIGS. 11A-20.

In some embodiments, method 3400 can further involve providing one ormore bends in sensor 138 to locate and/or hold sensor 138 in a desiredorientation with respect to electronic assembly substrate 630, aspreviously described in connection with FIGS. 11A-20.

Method 3400 can further comprise, for example, forming a first bend1202, 1302 in analyte sensor 138 such that a portion of the elongatedbody distal of first bend 1202, 1302 extends substantially parallel to aplane of electronics assembly substrate 630 and a portion of theelongated body proximal to first bend 1202, 1302 extends substantiallyperpendicular to the plane of electronics assembly substrate 630 and atleast partially into electronics assembly substrate 630. In someembodiments, lower housing 622 can comprise recess 1216, and method 3400can further comprise extending at least some of the portion of theelongated body proximal to first bend 1202 through electronics assemblysubstrate 630 and into recess 1206. In some embodiments, the portion ofthe elongated body proximal to first bend 1302 exerts a biasing forceF_(bias) against a portion of electronics assembly substrate 630,thereby securing analyte sensor 138 in a desired orientation withrespect to electronics assembly substrate 630.

In some embodiments, method 3400 can further comprise, for example,forming first bend 1402, 1502, 1602 in analyte sensor 138 such that aportion of the elongated body distal of first bend 1402, 1502, 1602extends substantially parallel to a plane of electronics assemblysubstrate 630 and a portion of the elongated body proximal to first bend1402, 1502, 1602 extends substantially perpendicular to the plane ofelectronics assembly substrate 630 and away from electronics assemblysubstrate 630. Lower housing 622 can further comprise recess 1416 in asidewall of lower housing 622, and method 3400 can further compriseextending at least some of the portion of the elongated body proximal tofirst bend 1402, 1502, 1602 within recess 1416, thereby restraininganalyte sensor 138 in a desired orientation with respect to electronicsassembly substrate 630. In some embodiments, the portion of theelongated body proximal to first bend 1502 exerts a biasing forceagainst a portion of lower housing 622, thereby securing analyte sensor138 in a desired orientation with respect to electronics assemblysubstrate 630.

In some embodiments, method 3400 can further comprise forming at leastone additional bend 1606, 1608, 1610 in analyte sensor 138 proximal tofirst bend 1602 such that additional bend(s) 1606, 1608, 1610 causes atleast a first part of the elongated body proximal to first bend 1602 anddistal to additional bend(s) 1606, 1608, 1610 to extend in a firstdirection within recess 1416 and exert a first biasing force F_(bias) ata first location along recess 1416, and at least a second part of theelongated body proximal to first bend 1602 and proximal to additionalbend(s) 1606, 1608, 1610 to extend in a second direction within recess1416 and exert a second biasing force F_(bias) at a second locationalong recess 1416, thereby securing analyte sensor 138 in a desiredorientation with respect to electronics assembly substrate 630.

In some embodiments, method 3400 can further comprise forming first bend1702, 1802, 1902, 2002 in analyte sensor 138 such that a portion of theelongated body distal of first bend 1702, 1802, 1902, 2002 extends in afirst direction substantially parallel to a plane of electronicsassembly substrate 630 and a portion of the elongated body proximal tofirst bend 1702, 1802, 1902, 2002 extends in a second direction that isdifferent from the first direction but also substantially parallel tothe plane of electronics assembly substrate 630.

In some embodiments, method 3400 can further comprise forming at leastone additional bend 1804, 1806 in analyte sensor 138 proximal to firstbend 1802 such that additional bend(s) 1804, 1806 cause at least a firstpart of the elongated body proximal to first bend 1802 and distal toadditional bend(s) 1804, 1806 to extend in the second direction andexert a first biasing force F_(bias) at a first location along one oflower housing 622 and electronics assembly substrate 630, and at least asecond part of the elongated body proximal to first bend 1802 andproximal to additional bend(s) 1804, 1806 to extend in a third directionsubstantially parallel to the plane of electronics assembly substrate630 and exert a second biasing force F_(bias) at a second location alongone of lower housing 622 and electronics assembly substrate 630, therebysecuring analyte sensor 138 in a desired orientation with respect toelectronics assembly substrate 630.

In some embodiments, electronic assembly substrate 630 can comprise post1912 and method 3400 can further comprise forming first bend 1902 in theanalyte sensor such that a portion of the elongated body distal of firstbend 1902 extends in a first direction substantially parallel to a planeof electronics assembly substrate 630 and a portion of the elongatedbody proximal to first bend 1902 extends substantially along a perimeterof post 1912, thereby securing analyte sensor 138 in a desiredorientation with respect to electronics assembly substrate 630.

In some embodiments, the portion of the elongated body distal of firstbend 2002 exerts a first biasing force F1 at a first location along oneof lower housing 622 and electronics assembly substrate 630, therebysecuring analyte sensor 138 in a desired orientation with respect toelectronics assembly substrate 630. First bend 2002 can exert a secondbiasing force F2 at a second location along one of lower housing 622 andelectronics assembly substrate 630, thereby further securing analytesensor 138 in the desired orientation. The portion of the elongated bodyproximal of first bend 2002 can exert a third biasing force F3 at athird location along one of lower housing 622 and electronics assemblysubstrate 630, thereby further securing analyte sensor 138 in thedesired orientation. In some embodiments, second biasing force F2 isexerted in a substantially opposite direction from third biasing forceF3, first biasing force F1 is exerted in a substantially perpendiculardirection to each of second biasing force F2 and third biasing force F3,first bend 2002 provides a first torque about first bend 2002 thatpushes the portion of the elongated body distal of first bend 2002against the first location, and/or first bend 2002 provides a secondtorque about first bend 2002 that pushes the portion of the elongatedbody proximal of first bend 2002 against the third location.

An example method 3500 for fabricating an analyte sensing apparatus willnow be described in connection with FIG. 35 below.

Block 3502 includes forming a housing comprising a cavity having a firstportion and a second portion. For example, as previously described inconnection with FIGS. 6A-10, lower housing 622 can be formed comprisingcavity 750 having first portion 752 and second portion 754.

Block 3504 includes forming a first dam in the first portion of thecavity adjacent to a first side of the first conductive contact. Forexample, first dam 2112 can be formed in a first portion of a cavityadjacent to a first side of first conductive contact 334.

Block 3506 includes forming a second dam in the first portion of thecavity adjacent to a second side of the first conductive contactopposite the first side, the first dam and the second dam defining afirst well encompassing the first conductive contact. For example,second dam 2114 can be formed in a first portion of a cavity adjacent toa second side of first conductive contact 334 opposite the first side.First dam 2112 and second dam 2114 define first well 2102 encompassingfirst conductive contact 334.

Block 3508 includes disposing an analyte sensor on the first dam and onthe second dam. For example, analyte sensor 138 can be disposed on firstdam 2112 and on second dam 2114.

Block 3510 includes coupling a first electrode of the analyte sensor tothe first conductive contact. For example, first electrode 212 b ofanalyte sensor 138 can be coupled to first conductive contact 334.

Block 3512 includes coupling a second electrode of the analyte sensor tothe second conductive contact. For example, second electrode 211 b ofanalyte sensor 138 can be coupled to second conductive contact 324.

In some embodiments, method 3500 can further comprise disposing anelectronics assembly substrate within the housing, wherein the first andsecond conductive contacts extend from the electronics assemblysubstrate into the first portion of the cavity. For example, electronicsassembly substrate 630 can be disposed within housing 622, wherein firstand second conductive contacts 324, 334 extend from electronics assemblysubstrate 630 into the first portion of the cavity (see, e.g., FIGS.6A-6C and 21A-21D).

In some embodiments, first dam 2112 and second dam 2114 each comprise asloped cross-section and analyte sensor 138 can rest on a lowest pointof the sloped cross-section of first dam 2112 and on a lowest point ofthe sloped cross-section of second dam 2114. The sloped cross-sectionscan be one of triangularly-recessed, parabolically-recessed,semi-circularly-recessed or hyperbolically-recessed cross-sections.

In some embodiments, method 3500 can further comprise disposingconductive epoxy 2122 over at least a portion of first conductivecontact 334 within first well 2102. Conductive epoxy 2122 is disposed atleast to a height of the lowest point of the sloped cross-section offirst dam 2112 or of the lowest point of the sloped cross-section ofsecond dam 2114 such that first electrode 212 b of analyte sensor 138 isin direct physical and electrical contact with conductive epoxy 2122when disposed on first dam 2112 and on second dam 2114.

An example method 3600 for fabricating an analyte sensing apparatushousing will now be described in connection with FIG. 36 below. Method3600 may correspond at least to the previous description in connectionwith FIGS. 22-27.

Block 3602 includes forming a first pocket in a housing having a firstpocket base. For example, lower housing 622 can be formed as previouslydescribed in connection with at least FIGS. 6A-10 and, as previouslydescribed in connection with FIGS. 22-27, first pocket 2400 a-c, 2700 ahaving first pocket base 2405 a-c can be formed in housing 622.

Block 3604 includes forming a first adjacent area in the housingabutting a first side of the first pocket, the first adjacent areahaving a first adjacent area base and a first transition between thefirst pocket base and the first adjacent area base. For example, firstadjacent area 2410 a-c, 2710 a abutting a first side of first pocket2400 a-c, 2700 a can be formed in housing 622. First adjacent area 2410a-c, 2710 a can have first adjacent area base 2415 a-c and a firsttransition 2404 a-c between first pocket base 2405 a-c and firstadjacent area base 2415 a-c.

Block 3608 includes forming a second adjacent area in the housingabutting a second side of the first pocket, the second adjacent areahaving a second adjacent area base and a second transition between thefirst pocket base and the second adjacent area base. For example, secondadjacent area 2420 a-c, 2720 abutting a second side of first pocket 2400a-c, 2700 a-b can be formed in housing 622. Second adjacent area 2420a-c, 2720 can have second adjacent area base 2425 a-c and secondtransition 2406 a-c between first pocket base 2405 a-c and secondadjacent area base 2420 a-c.

In some embodiments, method 3600 can further comprise disposingelectronics assembly substrate 630 within housing 622.

In some embodiments, first pocket 2400 a-c, 2700 a can have any of asubstantially rectangular-shaped (e.g., 2300 a), diamond-shaped (e.g.,2300 c), or polygonal-shaped (e.g., 2300 c) geometry such that sidewallsof first pocket 2400 a-c, 2700 a are substantially planar and meet oneanother to form angled corners. Alternatively, first pocket 2400 a-c,2700 a can have any of a substantially rounded rectangular-shaped (e.g.,2300 b), rounded diamond-shaped, or rounded polygonal-shaped geometrysuch that portions of sidewalls of first pocket 2400 a-c, 2700 a aresubstantially planar while other portions of the sidewalls that connectthe substantially planar portions are curved.

In some embodiments, as described in connection with at least callout“F” of FIG. 22 and the “step up” views of FIGS. 24 and 25, at least oneof first adjacent area base and the second adjacent area base aredisposed at an elevated height “h” compared to the first pocket basesuch that at least one of first transition 2204 f, 2404 c and secondtransition 2206 f, 2406 c step up from the first pocket base. In someembodiments, the elevated height “h” is approximately 0.5 millimeters.In some embodiments, first predetermined amount of epoxy 2430 c forms anupward-inflecting meniscus 2432 c at first and second transitions 2404c, 2406 c and the elevated height “h” exceeds a height ofupward-inflecting meniscus 2432 c. In some embodiments, elevated height“h” is a function of the first predetermined amount and at least one ofa viscosity, a surface energy and a surface tension characteristic ofepoxy 2430 c.

In some embodiments, as described in connection with at least callout“P” of FIG. 22 and the “flush” views of FIGS. 24 and 25, at least one ofthe first adjacent area base and the second adjacent area base aredisposed at a same height as the first pocket base such that at leastone of first transition 2204 p, 2404 b and second transition 2206 p,2406 b are flush with the first pocket base.

In some embodiments, as described in connection with at least callout“E” of FIG. 22, the “step-down” views of FIGS. 24 and 25, and FIG. 27,at least one of the first adjacent area base and the second adjacentarea base are disposed at a lower height “h” compared to the firstpocket base such that at least one of first transition 2204 e, 2404 aand second transition 2206 e, 2406 a step down from the first pocketbase. In some embodiments, lower height “h” is approximately 0.5millimeters. In some embodiments, first predetermined amount of epoxy2430 a forms a downward-inflecting meniscus 2432 a at first and secondtransitions 2404 a, 2406 a, thereby causing epoxy 2430 a to adhere tothe at least one of first and second transitions 2404 a, 2406 a andpreventing epoxy 2430 c from creeping into first 2210 e, 2410 a, 2710 aand second 2220 e, 2420 a, 2720 adjacent areas.

In some embodiments, first adjacent area 2410 a-c, 2710 a and secondadjacent area 2420 a-c, 2720 can have any of the geometries describedabove for the pockets. In some embodiments, one or more sidewalls 2402a-c of first pocket 2400 a-c are disposed substantially perpendicular tothe first pocket base, or alternatively, at an angle from substantiallyperpendicular to the first pocket base. In some embodiments, one or moresidewalls 2412 a-c, 2422 a-c of first and second adjacent areas 2410a-c, 2420 a-c are disposed substantially perpendicular to the respectivefirst and second adjacent area bases, or alternatively, at an angle fromsubstantially perpendicular to the first and second adjacent area bases.In some embodiments, one or more sidewalls 2408 c of first and secondtransitions 2404 a-c, 2406 a-c are disposed substantially perpendicularto the first pocket base, or alternatively, at an angle fromsubstantially perpendicular to the first pocket base.

In some embodiments, sidewalls 2408 c of at least one of first andsecond transitions 2404 a-c, 2406 a-c are rounded such that angledcorners are not formed at first and second transitions 2404 a-c, 2406a-c.

In some embodiments, a first width of first transition 2404 a-c and asecond width of second transition 2406 a-c are substantially within therange of 0.5 mm and 2.0 mm. In some embodiments, the first width offirst transition 2404 a-c is greater than the second width of secondtransition 2406 a-c. In some other embodiments, the first width of firsttransition 2404 a-c is less than the second width of second transition2406 a-c.

In some embodiments, method 3600 can further include, for example,disposing conductive contact 324, 334 in first adjacent area 2710 a orin second adjacent area 2720 of electronics assembly substrate 630. Insome embodiments, analyte sensor 138 comprises first electrode 211 b andsecond electrode 212 b, and method 3600 can further comprise, forexample, disposing analyte sensor 138 on housing 622 and electricallyconnecting at least one of first electrode 211 b and second electrode212 b with conductive contacts 324, 334.

In some embodiments, as previously described in connection with at leastFIG. 27, method 3600 can further include, for example, disposing post2712 in first adjacent area 2710 b or in second adjacent area 2720,disposing a second predetermined amount of epoxy on post 2712, anddisposing a portion of analyte sensor 138 in the second predeterminedamount of epoxy on post 2712. The second predetermined amount of epoxyexerts a centering force on the portion of analyte sensor 138 disposedtherein such that analyte sensor 138 is aligned substantially along acenterline of post 2712. Post 2712 can have a substantially symmetricalgeometry about a centerline of post 2712.

In some embodiments, method 3600 can further include providing thepocket base with a first surface energy and providing the first adjacentarea base with a second surface energy different from the first surfaceenergy. For example, as previously described in connection with FIGS.40A-40B, pocket base 4005 a-b can have a first surface energy and firstadjacent area base 4015 a-b can have a second surface energy differentfrom the first surface energy.

In some embodiments, method 3600 can further include providing thesecond adjacent area base with one of the second surface energy and athird surface energy different from the first and second surfaceenergies. For example, as previously described in connection with FIGS.40A-40B, second adjacent area base 4025 a-b can have one of the secondsurface energy and a third surface energy different from the first andsecond surface energies.

An example method 3700 for fabricating an analyte sensing apparatus willnow be described in connection with FIG. 37 below. Method 3700 may alsocorrespond at least to the previous description in connection with FIGS.22-27.

Block 3702 includes forming a housing comprising a first pocket having afirst pocket base, a first adjacent area abutting a first side of thefirst pocket, the first adjacent area having a first adjacent area baseand a first transition between the first pocket base and the firstadjacent area base, a second adjacent area abutting a second side of thefirst pocket, the second adjacent area having a second adjacent areabase and a second transition between the first pocket base and thesecond adjacent area base, and a conductive contact disposed in thefirst adjacent area or in the second adjacent area. For example, lowerhousing 622 can be formed as previously described in connection with atleast FIGS. 6A-10 and, as previously described in connection with FIGS.22-27, first pocket 2400 a-c, 2700 a having first pocket base 2405 a-ccan be formed in housing 622. First adjacent area 2410 a-c, 2710 aabutting a first side of first pocket 2400 a-c, 2700 a can be formed inhousing 622. First adjacent area 2410 a-c, 2710 a can have firstadjacent area base 2415 a-c and a first transition 2404 a-c betweenfirst pocket base 2405 a-c and first adjacent area base 2415 a-c. Secondadjacent area 2420 a-c, 2720 abutting a second side of first pocket 2400a-c, 2700 a-b can be formed in housing 622. Second adjacent area 2420a-c, 2720 can have second adjacent area base 2425 a-c and secondtransition 2406 a-c between first pocket base 2405 a-c and secondadjacent area base 2420 a-c. Conductive contact(s) 324, 334 can bedisposed in first adjacent area 2410 a-c or in second adjacent area 2420a-c.

Block 3704 includes disposing an electronics assembly substrate withinthe housing and electrically coupling the electronics assembly substrateto the conductive contact. For example, electronics assembly substrate630 can be disposed within housing 622 electronics assembly substrate630 can be electrically coupled to conductive contact(s) 324, 334.

Block 3706 includes disposing an analyte sensor comprising at least oneelectrode in electrical communication with the conductive contact. Forexample, analyte sensor 138 comprises at least one electrode 211 b, 212b, which can be disposed in electrical communication with conductivecontact(s) 324, 344.

Block 3708 includes disposing epoxy on the first pocket base, the epoxysecuring at least a portion of the analyte sensor to the first pocketbase. For example, epoxy can be disposed on first pocket base 2405 a-csuch that the epoxy secures at least a portion of analyte sensor 138 tofirst pocket base 2405 a-c.

In some embodiments, as described in connection with at least callout“F” of FIG. 22 and the “step up” views of FIGS. 24 and 25, at least oneof first adjacent area base and the second adjacent area base aredisposed at an elevated height “h” compared to the first pocket basesuch that at least one of first transition 2204 f, 2404 c and secondtransition 2206 f, 2406 c step up from the first pocket base. In someembodiments, first predetermined amount of epoxy 2430 c forms anupward-inflecting meniscus 2432 c at first and second transitions 2404c, 2406 c and the elevated height “h” exceeds a height ofupward-inflecting meniscus 2432 c.

In some embodiments, as described in connection with at least callout“P” of FIG. 22 and the “flush” views of FIGS. 24 and 25, at least one ofthe first adjacent area base and the second adjacent area base aredisposed at a same height as the first pocket base such that at leastone of first transition 2204 p, 2404 b and second transition 2206 p,2406 b are flush with the first pocket base.

In some embodiments, as described in connection with at least callout“E” of FIG. 22, the “step-down” views of FIGS. 24 and 25, and FIG. 27,at least one of the first adjacent area base and the second adjacentarea base are disposed at a lower height “h” compared to the firstpocket base such that at least one of first transition 2204 e, 2404 aand second transition 2206 e, 2406 a step down from the first pocketbase. In some embodiments, first predetermined amount of epoxy 2430 aforms a downward-inflecting meniscus 2432 a at first and secondtransitions 2404 a, 2406 a, thereby causing epoxy 2430 a to adhere tothe at least one of first and second transitions 2404 a, 2406 a andpreventing epoxy 2430 c from creeping into first 2210 e, 2410 a, 2710 aand second 2220 e, 2420 a, 2720 adjacent areas.

An example method 3800 for fabricating an analyte sensing apparatus willnow be described in connection with FIG. 38 below. Method 3800 maycorrespond to embodiments at least as previously discussed in connectionwith FIGS. 30A-30B.

Block 3802 includes forming a housing comprising an aperture thatdefines a cavity having a first portion and a second portion in thehousing. For example, as previously described in connection with FIGS.6A-10, lower housing 622 can be formed comprising aperture 626 thatdefines cavity 750 having first portion 752 and second portion 754 inlower housing 622.

Block 3804 includes disposing a first heat-sealable thermoplasticelastomer along a perimeter of the first portion of the cavity. Forexample, first heat-sealable thermoplastic elastomer 3002 can bedisposed along a perimeter of first portion 752 of cavity 750.

Block 3806 includes disposing at least a portion of an analyte sensorwithin the first portion of the cavity. For example, at least a proximalportion of analyte sensor 138 can be disposed within first portion 752of cavity 750.

Block 3810 includes fitting a cap on or within the aperture and over thefirst portion of the cavity, the cap comprising a second heat-sealablethermoplastic elastomer along at least a portion of the cap disposedover a border between the first and second portions of the cavity. Forexample, cap 3004 can comprise second heat-sealable thermoplasticelastomer 3006 along at least a portion of cap 3004 disposed over aborder between first 752 and second 754 portions of cavity 750. Cap 3004can be fitted on or within aperture 626 and over first portion 752 ofcavity 750.

Block 3812 includes melting the first and second heat-sealablethermoplastic elastomers, thereby sealing the first portion of thecavity from moisture ingress. For example, first 3002 and second 3006heat-sealable thermoplastic elastomers can be melted, for example byexposure to a laser or a similar heat source, thereby sealing firstportion 752 of cavity 750 from moisture ingress. In some embodiments,the border between first 752 and second 754 portions of cavity 750comprises a portion of first heat-sealable thermoplastic elastomer 3002.

An example method for fabricating an analyte sensing apparatus will nowbe described in connection with FIG. 39 below. Method 3900 maycorrespond to embodiments at least as previously discussed in connectionwith FIGS. 31 and 32.

Block 3902 includes forming a housing comprising an aperture thatdefines a housing cavity in the housing. For example, lower housing 622can be formed comprising aperture 626 that defines cavity 750 in lowerhousing 622.

Block 3904 includes disposing a first conductive contact and a secondconductive contact in the housing cavity. For example, first conductivecontact 324 and second conductive contact 334 can be disposed withincavity 750.

Block 3906 includes placing a first electrode of an analyte sensor onthe first conductive contact. For example, first electrode 211 b ofanalyte sensor 138 can be placed on first conductive contact 324.

Block 3908 includes placing a second electrode of the analyte sensor onthe second conductive contact. For example, second electrode 212 b ofanalyte sensor 138 can be placed on second conductive contact 334.

Block 3910 includes providing a cap comprising a base and a sealingmaterial comprising a first cavity and a second cavity. For example, cap3100, 3200 can include base 3102, 3202 and sealing material 2104, 3204comprising a first cavity and a second cavity.

Block 3912 includes fitting the cap on or within the aperture such thatthe sealing material at least partially fills the housing cavity andpresses against the housing, the first cavity aligns over the firstelectrode and the first conductive contact, and the second cavity alignsover the second electrode and the second conductive contact. Forexample, cap 3100, 3200 can be fit on or within aperture 626 such thatsealing material 3104, 3204 fills or partially fills cavity 750 aboveelectronics assembly substrate 630 and presses against electronicsassembly substrate 630, the first cavity aligns over first electrode 211b and first conductive contact 324, and the second cavity aligns oversecond electrode 212 b and second conductive contact 334.

In some embodiments, method 3900 may further comprise, before fittingcap 3100 on or within aperture 626, disposing first conductiveelastomeric puck 3106 in the first cavity, and disposing secondconductive elastomeric puck 3108 in the second cavity. First conductiveelastomeric puck 3106 is configured to press against first electrode 211b and first conductive contact 324 when cap 3100 is fitted on or withinaperture 626, thereby securing first electrode 211 b to first conductivecontact 324. Second conductive elastomeric puck 3108 is configured topress against second electrode 212 b and second conductive contact 334when cap 3100 is fitted on or within aperture 626, thereby securingsecond electrode 212 b to second conductive contact 334. In someembodiments, first and second conductive elastomeric pucks 3106, 3108have a substantially cylindrical shape.

In some embodiments, base 3202 of cap 3200 further comprises at leastfirst hole 3216 that aligns laterally with first cavity 3210 and secondhole 3218 that aligns laterally with second cavity 3212. At least aportion of sealing material 3204 physically isolates first hole 3216from first cavity 3210 and second hole 3218 from second cavity 3212. Insome embodiments, method 3900 may further comprise injecting conductiveepoxy 3206 into first cavity 3210 through first hole 3216 and throughthe portion of sealing material 3204, thereby electrically connectingfirst electrode 211 b to first conductive contact 324 and injectingconductive epoxy 3208 into second cavity 3212 through second hole 3218and through the portion of sealing material 3204, thereby electricallyconnecting second electrode 212 b to second conductive contact 334. Insome embodiments, first and second cavities 3210, 3212 have asubstantially conical shape.

The connections between the elements shown in some figures illustrateexemplary communication paths. Additional communication paths, eitherdirect or via an intermediary, may be included to further facilitate theexchange of information between the elements. The communication pathsmay be bi-directional communication paths allowing the elements toexchange information.

Various operations of methods described above may be performed by anysuitable means capable of performing the operations, such as varioushardware and/or software component(s), circuits, and/or module(s).Generally, any operations illustrated in the figures may be performed bycorresponding functional means capable of performing the operations.

The various illustrative logical blocks, modules and circuits describedin connection with the present disclosure (such as the blocks of FIG. 2)may be implemented or performed with a digital signal processor (DSP),an application specific integrated circuit (ASIC), a field programmablegate array signal (FPGA) or other programmable logic device (PLD),discrete gate or transistor logic, discrete hardware components or anycombination thereof designed to perform the functions described herein.A processor may be a microprocessor, but in the alternative, theprocessor may be any commercially available processor, controller,microcontroller or state machine. A processor may also be implemented asa combination of computing devices, e.g., a combination of a DSP and amicroprocessor, a plurality of microprocessors, one or moremicroprocessors in conjunction with a DSP core, or any other suchconfiguration.

In one or more aspects, various functions described may be implementedin hardware, software, firmware, or any combination thereof. Ifimplemented in software, the functions may be stored on or transmittedover as one or more instructions or code on a computer-readable medium.Computer-readable media includes both computer storage media andcommunication media including any medium that facilitates transfer of acomputer program from one place to another. A storage media may be anyavailable media that can be accessed by a computer. By way of example,and not limitation, such computer-readable media can comprise varioustypes of RAM, ROM, CD-ROM or other optical disk storage, magnetic diskstorage or other magnetic storage devices, or any other medium that canbe used to carry or store desired program code in the form ofinstructions or data structures and that can be accessed by a computer.Also, any connection is properly termed a computer-readable medium. Forexample, if the software is transmitted from a website, server, or otherremote source using a coaxial cable, fiber optic cable, twisted pair,digital subscriber line (DSL), or wireless technologies such asinfrared, radio, and microwave, then the coaxial cable, fiber opticcable, twisted pair, DSL, or wireless technologies such as infrared,radio, WiFi, Bluetooth®, RFID, NFC, and microwave are included in thedefinition of medium. Disk and disc, as used herein, includes compactdisc (CD), laser disc, optical disc, digital versatile disc (DVD),floppy disk and Blu-ray® disc where disks usually reproduce datamagnetically, while discs reproduce data optically with lasers. Thus, insome aspects a computer readable medium may comprise non-transitorycomputer readable medium (e.g., tangible media). In addition, in someaspects a computer readable medium may comprise transitory computerreadable medium (e.g., a signal). Combinations of the above should alsobe included within the scope of computer-readable media.

Certain aspects may comprise a computer program product for performingthe operations presented herein. For example, such a computer programproduct may comprise a computer readable medium having instructionsstored (and/or encoded) thereon, the instructions being executable byone or more processors to perform the operations described herein. Forcertain aspects, the computer program product may include packagingmaterial.

Software or instructions may also be transmitted over a transmissionmedium. For example, if the software is transmitted from a website,server, or other remote source using a coaxial cable, fiber optic cable,twisted pair, digital subscriber line (DSL), or wireless technologiessuch as infrared, radio, and microwave, then the coaxial cable, fiberoptic cable, twisted pair, DSL, or wireless technologies such asinfrared, radio, and microwave are included in the definition oftransmission medium.

Further, it should be appreciated that modules and/or other appropriatemeans for performing the methods and techniques described herein can bedownloaded and/or otherwise obtained by a user terminal and/or basestation as applicable. For example, such a device can be coupled to aserver to facilitate the transfer of means for performing the methodsdescribed herein. Alternatively, various methods described herein can beprovided via storage means (e.g., RAM, ROM, a physical storage mediumsuch as a compact disc (CD) or floppy disk, etc.), such that a userterminal and/or base station can obtain the various methods uponcoupling or providing the storage means to the device. Moreover, anyother suitable technique for providing the methods and techniquesdescribed herein to a device can be utilized.

It is to be understood that the claims are not limited to the preciseconfiguration and components illustrated above. Various modifications,changes and variations may be made in the arrangement, operation anddetails of the methods and apparatus described above without departingfrom the scope of the claims.

Unless otherwise defined, all terms (including technical and scientificterms) are to be given their ordinary and customary meaning to a personof ordinary skill in the art and are not to be limited to a special orcustomized meaning unless expressly so defined herein. It should benoted that the use of particular terminology when describing certainfeatures or aspects of the disclosure should not be taken to imply thatthe terminology is being re-defined herein to be restricted to includeany specific characteristics of the features or aspects of thedisclosure with which that terminology is associated. Terms and phrasesused in this application, and variations thereof, especially in theappended claims, unless otherwise expressly stated, should be construedas open ended as opposed to limiting. As examples of the foregoing, theterm ‘including’ should be read to mean ‘including, without limitation,’including but not limited to,' or the like; the term ‘comprising’ asused herein is synonymous with ‘including,’ containing,' or‘characterized by,’ and is inclusive or open-ended and does not excludeadditional, unrecited elements or method steps; the term ‘having’ shouldbe interpreted as ‘having at least;’ the term ‘includes’ should beinterpreted as ‘includes but is not limited to;’ the term ‘example’ isused to provide exemplary instances of the item in discussion, not anexhaustive or limiting list thereof; adjectives such as ‘known’,‘normal’, ‘standard’, and terms of similar meaning should not beconstrued as limiting the item described to a given time period or to anitem available as of a given time, but instead should be read toencompass known, normal, or standard technologies that may be availableor known now or at any time in the future; and use of terms like‘preferably,’ preferred,“desired,” or ‘desirable,’ and words of similarmeaning should not be understood as implying that certain features arecritical, essential, or even important to the structure or function ofthe invention, but instead as merely intended to highlight alternativeor additional features that may or may not be utilized in a particularembodiment of the invention. Likewise, a group of items linked with theconjunction ‘and’ should not be read as requiring that each and everyone of those items be present in the grouping, but rather should be readas ‘and/or’ unless expressly stated otherwise. Similarly, a group ofitems linked with the conjunction ‘or’ should not be read as requiringmutual exclusivity among that group, but rather should be read as‘and/or’ unless expressly stated otherwise.

Where a range of values is provided, it is understood that the upper andlower limit and each intervening value between the upper and lower limitof the range is encompassed within the embodiments.

With respect to the use of substantially any plural and/or singularterms herein, those having skill in the art can translate from theplural to the singular and/or from the singular to the plural as isappropriate to the context and/or application. The varioussingular/plural permutations may be expressly set forth herein for sakeof clarity. The indefinite article “a” or “an” does not exclude aplurality. A single processor or other unit may fulfill the functions ofseveral items recited in the claims. The mere fact that certain measuresare recited in mutually different dependent claims does not indicatethat a combination of these measures cannot be used to advantage. Anyreference signs in the claims should not be construed as limiting thescope.

It will be further understood by those within the art that if a specificnumber of an introduced claim recitation is intended, such an intentwill be explicitly recited in the claim, and in the absence of suchrecitation no such intent is present. For example, as an aid tounderstanding, the following appended claims may contain usage of theintroductory phrases “at least one” and “one or more” to introduce claimrecitations. However, the use of such phrases should not be construed toimply that the introduction of a claim recitation by the indefinitearticles “a” or “an” limits any particular claim containing suchintroduced claim recitation to embodiments containing only one suchrecitation, even when the same claim includes the introductory phrases“one or more” or “at least one” and indefinite articles such as “a” or“an” (e.g., “a” and/or “an” should typically be interpreted to mean “atleast one” or “one or more”); the same holds true for the use ofdefinite articles used to introduce claim recitations. In addition, evenif a specific number of an introduced claim recitation is explicitlyrecited, those skilled in the art will recognize that such recitationshould typically be interpreted to mean at least the recited number(e.g., the bare recitation of “two recitations,” without othermodifiers, typically means at least two recitations, or two or morerecitations). Furthermore, in those instances where a conventionanalogous to “at least one of A, B, and C, etc.” is used, in generalsuch a construction is intended in the sense one having skill in the artwould understand the convention, e.g., as including any combination ofthe listed items, including single members (e.g., “a system having atleast one of A, B, and C” would include but not be limited to systemsthat have A alone, B alone, C alone, A and B together, A and C together,B and C together, and/or A, B, and C together, etc.). In those instanceswhere a convention analogous to “at least one of A, B, or C, etc.” isused, in general such a construction is intended in the sense one havingskill in the art would understand the convention (e.g., “a system havingat least one of A, B, or C” would include but not be limited to systemsthat have A alone, B alone, C alone, A and B together, A and C together,B and C together, and/or A, B, and C together, etc.). It will be furtherunderstood by those within the art that virtually any disjunctive wordand/or phrase presenting two or more alternative terms, whether in thedescription, claims, or drawings, should be understood to contemplatethe possibilities of including one of the terms, either of the terms, orboth terms. For example, the phrase “A or B” will be understood toinclude the possibilities of “A” or “B” or “A and B.”

All numbers expressing quantities of ingredients, reaction conditions,and so forth used in the specification are to be understood as beingmodified in all instances by the term ‘about.’ Accordingly, unlessindicated to the contrary, the numerical parameters set forth herein areapproximations that may vary depending upon the desired propertiessought to be obtained. At the very least, and not as an attempt to limitthe application of the doctrine of equivalents to the scope of anyclaims in any application claiming priority to the present application,each numerical parameter should be construed in light of the number ofsignificant digits and ordinary rounding approaches.

All references cited herein are incorporated herein by reference intheir entirety. To the extent publications and patents or patentapplications incorporated by reference contradict the disclosurecontained in the specification, the specification is intended tosupersede and/or take precedence over any such contradictory material.

Headings are included herein for reference and to aid in locatingvarious sections. These headings are not intended to limit the scope ofthe concepts described with respect thereto. Such concepts may haveapplicability throughout the entire specification.

Furthermore, although the foregoing has been described in some detail byway of illustrations and examples for purposes of clarity andunderstanding, it is apparent to those skilled in the art that certainchanges and modifications may be practiced. Therefore, the descriptionand examples should not be construed as limiting the scope of theinvention to the specific embodiments and examples described herein, butrather to also cover all modification and alternatives coming with thetrue scope and spirit of the invention.

Various system and methods described may be fully implemented and/orcontrolled in any number of computing devices. Typically, instructionsare laid out on computer readable media, generally non-transitory, andthese instructions are sufficient to allow a processor in the computingdevice to implement the method of the invention. The computer readablemedium may be a hard drive or solid state storage having instructionsthat, when run, are loaded into random access memory. Inputs to theapplication, e.g., from the plurality of users or from any one user, maybe by any number of appropriate computer input devices. For example,users may employ a keyboard, mouse, touchscreen, joystick, trackpad,other pointing device, or any other such computer input device to inputdata relevant to the calculations. Data may also be input by way of aninserted memory chip, hard drive, flash drives, flash memory, opticalmedia, magnetic media, or any other type of file—storing medium. Theoutputs may be delivered to a user by way of a video graphics card orintegrated graphics chipset coupled to a display that maybe seen by auser. Alternatively, a printer may be employed to output hard copies ofthe results. Given this teaching, any number of other tangible outputswill also be understood to be contemplated by the invention. Forexample, outputs may be stored on a memory chip, hard drive, flashdrives, flash memory, optical media, magnetic media, or any other typeof output. It should also be noted that the invention may be implementedon any number of different types of computing devices, e.g., personalcomputers, laptop computers, notebook computers, net book computers,handheld computers, personal digital assistants, mobile phones, smartphones, tablet computers, and also on devices specifically designed forthese purpose. In one implementation, a user of a smart phone orwi-fi—connected device downloads a copy of the application to theirdevice from a server using a wireless Internet connection. Anappropriate authentication procedure and secure transaction process mayprovide for payment to be made to the seller. The application maydownload over the mobile connection, or over the WiFi or other wirelessnetwork connection. The application may then be run by the user. Such anetworked system may provide a suitable computing environment for animplementation in which a plurality of users provide separate inputs tothe system and method. In the below system where factory calibrationschemes are contemplated, the plural inputs may allow plural users toinput relevant data at the same time.

What is claimed is:
 1. An analyte sensing apparatus, comprising: ahousing comprising: a cavity having a first portion and a secondportion; a first conductive contact disposed in the first portion of thecavity, a second conductive contact disposed in the first portion of thecavity; a first well encompassing the first conductive contact, thefirst well defined by: a first dam disposed adjacent to a first side ofthe first conductive contact, and a second dam disposed adjacent to asecond side of the first conductive contact opposite the first side; andan analyte sensor comprising: an elongated body, a first electrode inelectrical communication with the first conductive contact, and a secondelectrode in electrical communication with the second conductivecontact, wherein the analyte sensor rests on the first dam and on thesecond dam.
 2. The apparatus of claim 1, further comprising anelectronics assembly substrate disposed within the housing, wherein thefirst conductive contact and the second conductive contact extend fromthe electronics assembly substrate into the first portion of the cavity.3. The apparatus of claim 1, wherein the first dam and the second dameach comprise a sloped cross-section, the analyte sensor resting on alowest point of the sloped cross-section of the first dam and on alowest point of the sloped cross-section of the second dam.
 4. Theapparatus of claim 1, wherein the sloped cross-sections of the first andsecond dams are one of triangularly-recessed, parabolically-recessed,semi-circularly-recessed or hyperbolically-recessed cross-sections. 5.The apparatus of claim 1, further comprising conductive epoxy disposedover at least a portion of the first conductive contact within the firstwell.
 6. The apparatus of claim 5, wherein the conductive epoxy isdisposed at least to a height of the lowest point of the slopedcross-section of the first dam or of the lowest point of the slopedcross-section of the second dam such that the first electrode of theanalyte sensor is in direct physical and electrical contact with theconductive epoxy.
 7. An analyte sensing apparatus, comprising: a housingcomprising an aperture that defines a cavity in the housing, the cavityhaving a first portion and a second portion; a first heat-sealablethermoplastic elastomer disposed along a perimeter of the first portionof the cavity; an analyte sensor having at least a portion disposedwithin the first portion of the cavity; and a cap configured to fit onor within the aperture and over the first portion of the cavity, the capcomprising a second heat-sealable thermoplastic elastomer along at leasta portion of the cap disposed over a border between the first and secondportions of the cavity, the first and second heat-sealable thermoplasticelastomers configured to seal the first portion of the cavity frommoisture ingress upon being melted.
 8. The apparatus of claim 7, whereinthe border between the first and second portions of the cavity comprisesa portion of the first heat-sealable thermoplastic elastomer.
 9. Ananalyte sensing apparatus, comprising: a housing comprising a cavity inthe housing; a first conductive contact; a second conductive contact; ananalyte sensor comprising: an elongated body; a first electrode inphysical contact with the first conductive contact; and a secondelectrode in physical contact with the second conductive contact; and acap configured to cover the cavity, the cap having a base; and a sealingmaterial configured to at least partially fill the cavity, the sealingmaterial comprising: a first cavity configured to align over the firstelectrode and the first conductive contact; and a second cavityconfigured to align over the second electrode and the second conductivecontact.
 10. The apparatus of claim 9, wherein the first cavity containsa first conductive elastomeric puck and the second cavity contains asecond conductive elastomeric puck.
 11. The apparatus of claim 10,wherein the first conductive elastomeric puck is configured to pressagainst the first electrode and the first conductive contact, and thesecond conductive elastomeric puck is configured to press against thesecond electrode and the second conductive contact.
 12. The apparatus ofclaim 10, wherein the first conductive elastomeric puck secures thefirst electrode to the first conductive contact and the secondconductive elastomeric puck secures the second electrode to the secondconductive contact.
 13. The apparatus of claim 10, wherein the firstconductive elastomeric puck is configured to press against the firstelectrode and the cap, and the second conductive elastomeric puck isconfigured to press against the second electrode and the secondconductive contact.
 14. The apparatus of claim 10, wherein the first andsecond conductive elastomeric pucks have a substantially cylindricalshape.
 15. The apparatus of claim 10, wherein the first conductivecontact has a gap formed within.
 16. The apparatus of claim 15, whereinthe first conductive elastomeric puck is disposed within the gap of thefirst conductive contact.
 17. The apparatus of claim 16, wherein thefirst conductive elastomeric puck is disposed within the gap of thefirst conductive contact by press fit.
 18. The apparatus of claim 9,wherein: the first cavity is configured to retain a first injection ofconductive epoxy configured to electrically couple the first electrodeand the first conductive contact; and the second cavity is configured toretain a second injection of conductive epoxy configured to electricallycouple the second electrode and the second conductive contact.
 19. Theapparatus of claim 9, wherein the base of the cap further comprises atleast a first hole that aligns laterally with the first cavity and asecond hole that aligns laterally with the second cavity, at least aportion of the sealing material physically isolating the first hole fromthe first cavity and the second hole from the second cavity.